U.S. Environmental Protection Agency
Mid-Continent Ecology Division
6201 Congdon Blvd
Duluth, MN. 55804
£
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33
V
A
EPA Research Vessel
LAKE EXPLORER II
DRYDOCK AND REPAIRS
DETAIL SPECIFICATION
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c of Contents
1. SCOPE: 3
2. GENERAL: 3
2.1. References 3
2.2. Requirements 3
2.3. Notes 4
3. BASIC ITEMS 5
3.1. ITEMNO. 301: Temporary Services 5
3.2. ITEM NO. 302: Drydock and Routine Drydock Work 6
3.3. ITEMNO. 303: MarineEngineering/Repower Services 7
3.4. ITEMNO. 304: Removal and Installation of Main Ship Propulsion System
3.5. ITEMNO. 305: Underwater Body Coating 10
3.6. ITEMNO. 306: Tailshafts & Bearings Inspection & Repairs 11
4. OPTIONAL ITEM 400: ADDITIONAL ITEM RE Ol i :STS .. 13
4.1. References 13
4.2. Government-Furnished Material 13
4.3. Requirements 13
4.4. Quality Assurance 13
4.5. Notes 13
5. OPTIONAL ITEMS 14
5.1. ITEMNO. 501: Hull Inspection I Itiasonic tests 14
5.2. ITEMNO. 502 Driplcss Shaft Seals 15
6. REFERENCES 16
6.1. STANDARD Sl»l ( 11 l( A I IONS 16
6.2. DRAWINGS 16
6.3. TECHNICAL MANI AI.S and OTIIIiR 16
6.4. GOYLRN'MLNT I I 'RNISIII I) MATERIAL 16
6.5. ATTACHMENTS 16
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1. SCOPE:
These Detail Specifications contain the requirements for dry dock repairs of the EPA
Research Vessel LAKE EXPLORER II.
2. GENERAL:
2.1. References
2.1.1. EPA Standard Specification EPA-000-1, "General Requirements lor Ship
Repair Contract Work on EPA Ships"
2.1.2. Asbestos Survey Report "SKMBTEPA BOAT.pdf \ dated January I 1. 2<) 1.1
2.1.3. EPA Standard Specification EPA-000-3, "Coating Systems for Steel Surfaces"
2.1.4. NOAA Ship RUDE Drawing RU-S9-0-1. "General Arrangement& Inboard
Profile"
2.2. Requirements
2.2.1. References 2.1.1 and 2.1.4 form apart of these Detail Specifications. All
provisions and requirements contained therein are applicable to all work items,
including all additional work items which are authorized by the Contracting Officer.
Primary specifications for work will be provide in the recommendations and
specifications provided by the Marine F.ngineering firm
2.2.2. The contractor may reduce the ship's drafts by offloading liquid loads and or
ballasting in order to provide the required clearances under the keel during transit to
and from the contractor's facility Oil tanks shall not be ballasted. After all work has
been completed, reload and trim the ship to the as-found conditions. The minimum
drafts which may be permitted are.
forward Draft 6 feet - 5 inches
After Draft ..6 feet - 5 inches
2.2.3. IYo\ ide and maintain a Quality Assurance (QA) TEST AND INSPECTION
PLAN applicable to all work items, including all additional work items which are
authorized by the Contracting Officer and update it weekly for each weekly progress
meeting The form shall include the following minimum information for each work
item and additional work item:
a Specillcation item and paragraph number
b Component/Equipment name
c l est or Inspection description
d Acceptance Criteria
e QA Inspection Report
2 2 4 ho\ ide a separate Test Schedule, and update it weekly for each weekly progress
meeting. Provide a copy to the COR 24-hours prior to the scheduled weekly
progress meeting.
2.2.5. Weigh all materials and items removed, installed, or relocated on the ship.
Provide a summary report to the COR indicating the total weight in pounds of the
item and a breakdown of their locations by space, deck, frame, distance from
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centerline, and height off of the deck. A sample form is attached to these
specifications.
2.2.6. Unless otherwise stated in these work items, prepare and coat all new steel and
disturbed painted surfaces in accordance with reference 2.1.4. Apply the appropriate
coating system to the area being coated as identified by paragraph 5 2 of this
reference except that the topcoat color shall match the surrounding area
2.2.7. Several Items affect the habitability of the ship. The ship's crew will make
berthing arrangements ashore the day after arrival and return the day before
departure.
2.3. Notes
2.3.1. Some items in this specification may require gas freeing of tanks, in order to
accomplish the required work. Prospecti\ e bidders should be careful not to duplicate
the costs of gas freeing where tank(s) are required lo be gas freed to perform work
in more than one item.
2.3.2. Reference 2.1.5 was use for locations and idenlilicalion of spaces in developing
these specifications.
2.3.3. Requirements and responsibilities regarding asbestos-containing materials (ACM)
are contained in reference 2.1 2 A copy may be re\ iewed on board the ship during
the prebid inspection or at the Ml- D-Duluth, 6201 Congdon Blvd, Duluth, MN.
55804, upon request
2.3.4. The following descripli\ e data of the ship is provided for information:
I .ength 0\ era 11 90 feet
Beam (Molded) . 22 feet
Propulsion Diesel, twin screw
Cruising Speed 9 knots
I-leet lie Ser\ ice 240 volts AC
Crew size 11
I lome Port Duluth, MN
l-ndurance 600 miles before refueling
2.3.5 Except as otherwise stated in this specification, the ship will be delivered to the
contractor's facility with the following maximum drafts and displacements at
approximately 50% liquid loading:
I 'orward Draft 6 feet - 9 inches
After Draft 7 feet - 8 inches
Displacement 220 LT
2.3.5. A copy of referenced technical manuals may be reviewed on board the ship
during the prebid inspection or at the MED-Duluth, 6201 Congdon Blvd, Duluth,
MN. 55804, upon request.
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2.3.6. A copy of referenced drawings are provided through the solicitation package or
may be reviewed at the MED-Duluth, 6201 Congdon Blvd, Duluth, MN. 55804,
upon request.
3. BASIC ITEMS
3.1. ITEM NO. 301: Temporary Services
3.1.1. References
a. EPA Standard Specification EPA-000-2, "Temporary Sua ices al Contractor's
Facilities"
3.1.2. Government-Furnished Material
a. None
3.1.3. Requirements
a. Provide all temporary services required in accordance with reference (a).
b. The following additional information and requirements apply:
1. The ship's crew will make berthing arrangements ashore the day after
arrival and return one day before llie scheduled departure.
2. Electric power requirements are 240 volts. AC. 3 phase, 60 hertz, 200 AMP
service maximum (75 AMP a\erage load)
3. Access to fax machine
4. Provide two vehicle parking spaces
5 The ship's toilet facilities will be secured and temporary toilet facilities will
be required
(•> Security sen ice is required Contract shall provide security guard service
during all periods that no contract work is being performed while ship on
contractors facilities
i:\DOI ITEM
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3.2. ITEM NO. 302: Drydock and Routine Drydock Work
3.2.1. References
(a) EPA Standard Specification EPA-000-4, "Drydocking and Routine Drydock
Work"
(b) NOAA Ship RUDE Drawing RU-S7-1-1, "Docking Plan"
(c) NOAA Ship RUDE Drawing RU-S5-0-2, "Offsets"
(d) NOAA Ship RUDE Drawing RU-S11-11-1, "Midship & Type Sections"
3.2.2. Requirements
a. Provide drydocking and routine drydock work in accordance with references
(a) and (b).
b. The following additional information and requirements apply:
1. When the ship lands on the keel Mocks, prior to hauling the ship out of the
water, the Contractor shall ascertain that the blocks are contacting the hull
properly and not landing on the bilge keels or transducers. Once the
landing position is satisfactory, hauling out may continue.
2. Install GFM packing instead of "TFE-ini|n egnated square flax packing",
as required in reference (a), para 3.8
3.2.3. Quality Assurance
a. No additional Requirements
3.2.4 Notes
a References (c) and (d) are identified as sources for obtaining information,
b If option Item No 3.6.3(d). is chosen post bid, then disregard stuffing box
marine packing requirements.
END Oi HEM
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3.3. ITEM NO. 303: Marine Engineering/Repower Services
3.3.1. References
(a) NOAA Ship RUDE Drawing RU-S11-3-1, "Floors & Frames1'
(b) NOAA Ship RUDE Drawing RU-S11-4-1, "Flat & V.C k Side Gilders, Stem,
Forepeak Framing & Skeg"
(c) NOAA Ship RUDE Drawing RU-S33-0-1, "Gen Arrgt Tank Top "B" Deck,
Messing Flat "C" Deck & Platf "D" Deck"
(d) Electronic drawings available, for 3.3.3 (b, c, & d)
3.3.2. Government-Furnished Material
a. NA
3.3.3. Requirements
The intent of this project is to provide expertise, labor, and materials to create a
document (blueprint) outlining the Re-powering of the 11 VLAKE EXPLORER
//with two new Tier 3 Main Engines, Reduction Gear, and auxiliary
equipment to complete the installation. Auxiliary equipment includes: all
systems from the pilot house to the propeller shaft affected by a designed
reduction and/or renewal of pipe work in conjunction with the engine/reduction
gear replacement. The contractor's plans/drawing will he used by independent
contractors to construct and install the new engines and gear. Additionally, the
engineering/naval architect firm will provide continuing technical
assistance'advice to EPA dining the installation of the new engine and
auxiliary equipment, to assist as needed in any design modifications, and in sea
trials to verify performance against design specifications.
3.3.4. I jiuineerinu Specifications
3.3 4 I l)e\elop a plan for the repower ofth e R/V LAKE EXPLORER II.
3 3 4 1 I New engines to meet Tier 111 EPA emissions standards.
3 3 4.1 2 Shall he fuel efficient, capable of operating on bio-fuels (minimum of
B 10 to maximum of B100).
3 3 4 I 3 Proper horsepower and reduction gearing to maintain at least design
speed of 11 knots. It is desired by EPA to achieve 12 knots as an
economical speed, as long as the fuel consumption doesn't exceed 37
gallons per hour.
3.3 4 I 4 The current fuel use at speed (10.2 kts) is 37 gallons per hour (includes
both engines).
3 3 4 1 5 The reduction gears sought by EPA are Twin Disk QuickShift
transmissions. The reduction gears must be able to couple with the
new engines and existing shafting.
3 3.4.1.6 Engine/reduction gear frame mounting and shafting alignment.
3 3 4.2 Current ship specifications;
3.3.4.2.1 The ship engines are Cummins KT-19M.
3.3.4.2.2 The rated horsepower is 425.
3.3.4.2.3 Engines drive a 3:1 Twin Disk Reduction gear.
3.3.4.2.4 The propeller shafts are 4 3/8" diameter, and 22' 1" in length.
3.3.4.2.5 The propellers are 4-blade, 42 inch diameter.
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3.3.4.3 Develop a plan to reduce redundant or obsolete pipe work within the engine
room.
3.3.4.3.1 This process is desired to eliminate piping no longer needed or never
used.
3.3.4.3.2 Examine which pipe that shall be retained and to be renewed.
3.3.4.4 Develop a plan for the install of dripless shaft seal system
3.3.4.5 Provide plans to remove old packing gland system
3.3.4.6 Installation of a dripless shaft seal system that is industry standard and low
maintenance.
3.3.5. Quality Assurance
3.3.4.1 The main engine repower design shall meet the minimum EPA emission
standards of Tier III. To include, recommendations for reduction and/or
renewal of engine room piping for auxiliary equipment
3.3.4.2 Provide EPA with a preliminary drawing for re\ iew Ix-lore accepting final
drawings.
3.3.4.3 The contractor shall be available to the ship yard representatives if any
questions regarding the supplied blueprints are needed.
3.3.6. Notes
3.3.4.4 Provide a recommendation lor the best I Jiui lie/reduction gear type and size
for this vessel. The contractor shall pro\ ide a list of acceptable configurations
including model numbers and manufacture's names so that the EPA with the
contractors help can select the best system for this application.
3.3.4.5 Pro\ ide 3 final copies of the Main Engine/ reduction gear install on a blue
print, with procedural recommendations, which can be provided to a
contractor for construction and installation.
3.3 4 (•> Provide a dripless shaft seal recommendation and install design.
3.3 4 7 Provide one CD-ROM with electronic drawings in PDF (or equivalent) format
and material list
3.3.4 S IYo\ ide an estimated weight calculation of new engines/reduction gear.
3 3.4 9 Pro\ ide technical assistance to oversee installation phases (done under
separate SOW ) and complete design modifications if requested by EPA.
3 3 4 11) Require new engines to be able to interface with existing Caterpillar
marine generator(s) and program software for monitoring and servicing.
3.3.4 II l-ngine type selected must be able serviced for repair or parts within a 6
hour window anywhere on the Great Lakes.
END OF ITEM
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3.4. ITEM NO. 304: Removal and Installation of Main Ship Propulsion System
3.4.1. References
(a) NOAA Ship RUDE Drawing RU-S11-3-1, "Floors & Frames1'
(b) NOAA Ship RUDE Drawing RU-S11-4-1, "Flat & V.C k Side Gilders, Stem,
Forepeak Framing & Skeg"
(c) NOAA Ship RUDE Drawing RU-S33-0-1, "Gen Arrgl Tank Top "B" Deck,
Messing Flat "C" Deck & Platf "D" Deck"
(d) Electronic drawings available, for 3.3.3 (b, c, & d)
(e) Marine Engineering drawings and specifications
3.4.2. Government-Furnished Material
a. NA
3.4.3. Requirements
a. General: Use Marine Engineering/Aivhilecls design and specifications.
3.4.4. Quality Assurance
a. Follow guidelines specified In Marine Engineer
3.4.5. Notes
a. Consult with engineering firm and engi ne maker for proper install and set up
of new equipment.
i:ndoi itim
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3.5. ITEM NO. 305: Underwater Body Coating
3.5.1. References
(a) EPA Standard Specification EPA-000-5, "Underwater Body Ablative Coating
System"
3.5.2. Government-Furnished Material
a. None
3.5.3. Requirements
a. Prepare the entire underwater body in accordance w ith reference (a). and coat
with a "maintenance system".
b. Prepare 300-square feet of the underwater body, the entire boottop. and all sea
chests in accordance with reference (a), and coat with a "complete system"
c. The following additional requirements apply:
1. Remove and install the hull zincs as interferences Note the location of the
hull zincs prior to removal.
2. Remove and install the stern rubber bumper pad. located between the port
and stbd bumper pipes, as interferences. Clean the rubber bumper pad of
all growth and debris prior to installation
3. Fair in hull transducers areas using Philadelphia Resins Corp.,
Montgomery, PA "Philk bond IJlue (t.\. 2 component epoxy compound",
or equal.
4. Coat all hull frame number and draft marks with a contrasting top coat
color (e.g.. white within the black boottop).
3.5.4. Quality Assurance
a \o additional requirements.
3.5.5. Notes
a The top edge of the existing 3 loot wide parabolic boottop is marked with 2
inch long welds on (¦> foot centers,
b If the COR designates a greater or lesser amount of the underwater body for a
"complete system" than the required 300-square feet, a contract modification
will be issued to increase or decrease the cost of this item. The cost adjustment
will be based on the unit price provided by the contractor on the initial bid
schedule.
c. The current "complete system" was installed September 2009 using the
International Paint Co. coating system,
d Ship's force may provide new hull zincs if required.
END OF ITEM
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3.6. ITEM NO. 306: Tailshafts & Bearings Inspection & Repairs
3.6.1. References
(a) EPA Standard Specification EPA-240-1, "Propulsion Shafts and Propellers"
(b) NOAA Ship RUDE Drawing Number AMC-3192, "Inboard Stern Tube
Bearing & Stuffing Box"
(c)NOAA Ship RUDE Drawing Number RU-S43-1-1. "Shafting. Coupling, Stern
Tube and Bearing - Arrangement and Details"
(d) EPA Standard Specification EPA-000-5, "Underwater IJody AMati\ e Coating
System"
3.6.2. Government-Furnished Material
a. None
3.6.3. Requirements
a. Perform the following work on the port and starboard propeller, stern tubes,
and tailshafts in accordance with reference (a)
1. Remove from the ship to an inside shop laci lity.
2. Perform the "In-shop Inspection of Propulsion Shaft" outlined in reference
(a).
3. Using a micrometer, measure the shaft bearing area diameters at four
locations along the length of bearing area C ompare the shaft bearing area
dimensions for respecti\ e new bearings.
4 Visually inspect the starboard shaft tube for excessive wear or corrosion.
5 Remo\ e all shaft bearings from both stern tubes.
(•> Replace the port and starboard shaft, strut, and stern tube bearings.
7 Install the port and starboard tailshafts in their original locations,
b While the propeller shafts are removed from the ship, renew the port shaft
tube as specified in NOAA Ship RUDE Drawing Number RU-S43-1-1,
"Shafting. Coupling, Stern Tube and Bearing - Arrangement and Details".
1 liefore removal of stern tube, take accurate measurements of the tube/shaft
alignment with reduction gear coupling and strut hub, to ensure the best
alignment for installation of new tube.
2 The shaft coupling in drawing is slightly different than current
configuration, there is no shaft clutch beyond the reduction gear.
c. 11" needed, Weld build up the packing gland area on the port and starboard
tailshafts. Machine the packing gland area to provide the proper clearance
between the shaft and the bearing,
d Match mark the port and starboard stuffing boxes and remove the stuffing
boxes from the ship to the shop.
I Clean the stuffing boxes of all growth, debris, and foreign material.
2. Inspect the stuffing boxes for damage and excessive wear that may affect
their performance.
3. Install the stuffing boxes in their original positions using new gaskets and
monel fasteners.
e. Optional to 3.6.3 d, replace the stuffing boxes with dripless shaft seals (See
option 502).
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f. After completion of all other associated work, install the port and starboard
propellers in their original positions.
3.6.4. Quality Assurance
a. Perform a one hour Dock Trial and four hour Sea Trial of I lie propulsion
shafting system. Adjust the tightness of the stuffing tube dining llie sea trial.
3.6.5. Notes
a. Tailshafts are AGUMET 22 material. There are no liners and no fiberglass
reinforced plastic coverings on these tail shafts
b. References (b) and (c) are listed as sources lor obtaining information
END OF TH AI
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4. OPTIONAL ITEM 400: ADDITIONAL ITEM REQUESTS
4.1. References
4.1.1. None
4.2. Government-Furnished Material
4.2.1. None.
4.3. Requirements
4.3.1. This item is a place holder only for all requirements dealing with emergent work
and changes associated with this contract
4.3.2. Provide an estimate of labor hours and material grow th lor emergent work
anticipated for this contract for each item listed
4.4. Quality Assurance
4.4.1. No additional requirements
4.5. Notes
4.5.1. No additional requirements.
ENDOI ITEM
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5. OPTIONAL ITEMS
5.1. ITEM NO. 501: Hull Inspection Ultrasonic tests
5.1.1. References
a. EPA Standard Specification EPA-000-1, "General Requirements for Ship
Repair Contract Work on EPA Ships"
5.1.2. Government Furnished Materials
a. None
5.1.3. Requirements
a. Perform non-destructive tests in select purl ions of the hull by direction of
COR or Master, using Ultrasonic (I T) methods.
b. Contractor shall provide up to 50 I T tests at the CORs discretion.
c. These UT tests will be for thickness gauging. w liich will require preparations
of steel surfaces for accurate UT readings.
d. The results of the UT readings shall be recorded as follows;
1. Prepare a table \\ liich lists for each gage reading llie location, actual
thickness, original thickness, percentage of wastage, and recommendations
(if any).
2. Prepare schematic diagrams of the shell plating, decks, bulkheads, and
other structural members which reflects the approximate location of each
reading and the actual reading obtained at each location.
b. Restore coating system lo that of which existed before the surfaces were
prepared.
c Submit 2 copies of tables and diagrams to the COR.
5.1.4. Quality Assurance
a None
5 1.5. Notes
a ()riginal hull thickness documentation will be provided after contract award
END OF ITEM
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5.2. ITEM NO. 502: Dripless Shaft Seals
5.2.1. References
a. Marine Engineering recommendations and Specifications
b. EPA Standard Specification EPA-000-1, "General Requirements lor Ship
Repair Contract Work on EPA Ships"
5.2.2. Government Furnished Materials
a. None
5.2.3. Requirement
a. Proceed with Marine Engineering recommendations and Specification
5.2.4. Quality Assurance
a. Seals install with shafts and no leaks u hen cooling water is applied after
installation.
b. No leaks when ship is undocked. A dockside trail shall be conducted for 30
minutes at various RPMs and inspect lor leaks and or heat.
c. A four hour sea trial to check for leaks and heat.
5.2.5. Notes
5.2 Original hull thickness documentation will be pro\ ided after contract award
em) or ri'LM
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6. REFERENCES
6.1. STANDARD SPECIFICATIONS
EPA-000-1, "General Requirements for Ship Repair Contract Work on EPA Ships"
EPA-000-3, "Coating Systems for Steel Surfaces"
EPA-000-2, "Temporary Services at Contractor's Facilities"
EPA-000-4, "Dry docking and Routine Dry dock Work"
EPA-000-5, "Underwater Body Ablative Coating System"
EPA-000-6, "Valve Overhaul and Test"
EPA-000-7, "Asbestos Containing Materials"
EPA-000-8, "General Requirements for Electrical/Electronic Items"
EPA-240-1, "Propulsion Shafts and Propellers"
6.2. DRAWINGS
RU-S9-0-1, "General Arrangement & Inboard Profile"
RU-S7-1-1, "Docking Plan"
RU-S5-0-2, "Offsets"
RU-S11-11-1, "Midship & Type Sections"
RU-S11-3-1, "Floors & Frames"
RU-S11-4-1, "Flat&V.C.K. - Side Girders. Stem. I'oiepeak haming & Skeg"
RU-S33-0-1, "Gen Arrgt - Tank Top "B" Deck. Messing I lal "( " Deck & Platf "D" Deck"
RU-S43-1-1, "Shafting. Coupling. Stern Tube and liearing Arrangement and Details"
AMC-3192, "Inboard Siern Tube Bearing & Siufling Box"
6.3. TEC I IMC.M. MAM AI.S and () 11II R
"Survey for Location of Asheslos-Conlaining Materials with Cost Estimate", dated January 4,
1993
0 4. (.()\ I KWII X I I I RN[SHED MATERIAL
I ISS-GFO-HI'MP-' i (I ligh Peilbrniance Marine packing)
I ISS-GFO-HPMP-d (HighPerformance Marine packing)
o 5. ATTACHMI ATS
\\ eight and Moment Summary Table
Docking Report
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EPA-000-1
March 2008
U.S. Environmental Protection Agency (USEPA)
Mid-Continent Ecology Division
STANDARD SPECIFICATION EPA-000-1
GENERAL REQUIREMENTS FOR SHIP REPAIR CONTRACT WORK ON EPA SHIPS
1. SCOPE. This specification contains the general requirements for
contract work by a Contractor on or for EPA ships assigned to the
Mid-Continent Ecology Division.
2. REFERENCES.
a. American Bureau of Shipping "Rules for Building and Classing
Steel Vessels"
b. U. S. Coast Guard "Subchapter F - Marine Engineering", 46
CFR 50 through 46 CFR 64.
c. U. S. Coast Guard "Subchapter J - Electrical Engineering",
4 6 CFR 110 through 4u _l_lo.
d. IEEE Std 45-1983, "IEEE Recommended Practice for Electric
Installations on Shipboard"
e. 40 CFR 61, Subpart M, sections 61.140 through 61.157
f. 29 CFR 1915.1001
§• EPA Standard Specification EPA-000-7(series), "Asbestos
Containing Materials"
3. DEFINITIONS. Whenever used herein or in other documents which
invoke this specification by reference, the following definitions
of terms apply:
3.1 Inspect. Visually evaluate the specified surface, item,
part, or component for evidence of contamination, damage
excessive wear, scoring, and any other condition which
could interfere with the proper operation or functioning of
the surface, item, part or component.
3.2 Install. Place the specified item in position for service
and make all connections needed to insure proper use,
service, appearance, and operation. Except as may otherwise
be specified, this shall include the following:
a. provide new or modify existing foundations. Securely
mount equipment and components using new fasteners.
Align connected equipments and components to meet
manufacturers' specifications.
b. Make all electrical connections. Provide new electric
cable runs between controllers and motors of new
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EPA-000-1
March 2008
equipment. Existing cables may be reused in other
applications, except where the existing cables are too
short to make connections. Renew cables which are too
short and less than 20 feet long. Junction boxes may be
used to increase the cable run length where the existing
cable runs are longer than 20 feet.
c. Modify new piping to suit the new equipment, including the
rerouting of existing piping and adding of new piping as
needed to properly connect equipment and components. Piping
modifications greater than five feet from the equipment are
not required. New piping is required only to the extent
necessary to accommodate modifications of existing piping.
3.3 Piping. A system of pipe, tube, elbows, tees, valves,
couplings, and other pipe fittings.
3.4 Rebuild. Disassemble, clean, inspect, repair (including
renewal of all parts needed) , reasseitujxe, test, and
calibrate the specified part, component, system, or machine
to restore it to a condition of reliability equivalent to a
new part, component, system, or machine. Components and
parts shall meet the manufacturer's applicable rebuild
specifications.
3.5 Reinstall. Return the same item which was previously
removed to its previous configuration and location.
3.6 Renew. Provide and install a new item as replacement for an
existing item previously removed or to be removed. The new
item must be the same as or comparable in material,
performance and configuration to the item removed.
3.7 Replace. Same as "renew", defined above.
. REQUIREMENTS.
4.1 Condition Reports.
4.1.1 A Condition Report shall be prepared and submitted by
the Contractor to the Contracting Officer's
Representative (COR) on all of the following
occasions:
a. Whenever specifically required by other documents.
b. Whenever the Contractor determines or notes that
additional work or material or other deviation is
necessary in order to produce a reliable or
complete repair.
c. Whenever defect or deficiencies are noted in
Government-furnished Property.
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EPA-000-1
March 2008
d. Whenever measurements, tests or inspections are
required by other specifications or procurement
documents, the results and findings shall be
documented on a Condition Report.
4.1.2 Condition Reports shall contain, as a minimum, the
following:
a. Name of the ship.
b. Contract number and related work item number.
c. Detail description of conditions observed,
including a record of all measurements taken and
other supporting data.
d. Recommendations of additional work and materials
deemed to be needed, if any. Do not include
pricing informatior .
e. Estimate of the impact on the completion of the
contract, if any.
4.1.3 Submit Condition Reports to the COR within twenty-
four hours after completing the measurements,
inspections, or tests, or after the need for
additional work or material is noted.
4.1.4 For work involving disassembling and inspection of
equipment, machinery or systems and for work
involving opening and inspection of tanks, the work
must be completed and a Condition Report must be
submitted during the first 25-percent of the work
performance period.
4 . 2 Progress Meetings.
4.2.1 Weekly progress meetings shall be held at a time and
place mutually agreeable to the COR and the
Contractor. As a minimum, the meetings shall be
attended by the COR and a Contractor's management
official having authority to make binding
commitments. Other interested parties may attend the
meetings as appropriate.
. . trior to the end of the work day preceding the
progress meeting, the Contractor shall submit to the
COR a preliminary progress report containing the
following information:
a. Percentage completion of each contract item,
including all additional work items authorized by
the Contracting Officer.
b. Notation of any problems which could impact timely
completion, including material delivery delays.
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4.3 Drawings, Specifications, Publications, and Other
References
4.3.1 Each solicitation or specification contains a list
of drawings and other references which are being
issued to prospective bidders. Except as otherwise
indicated, other referenced drawings,
specifications, manuals, handbooks, instructions,
publications, and standards will not be issued. When
available, references may be reviewed onboard the
ship or at the Marine Engineering Branch, Atlantic
Marine Center, 439 W. York St., Norfolk, VA, 23510.
4.3.2 The Contractor shall be responsible for obtaining
all references not issued by the solicitation or
otherwise made available for review by the
government. Failure of the Contractor to obtain a
reference does not relieve Liie contractor's
responsibility to comply with the reference.
4.3.3 Whenever reference is made to a specific edition or
revision of a drawing, specification, manual,
publication, or other reference document, the
specified edition or revision shall apply. When an
edition or revision is not specified, the edition or
revision in effect on the date of the solicitation
shall apply.
4.4 Personnel Information. Provide to the COR a list of the
Contractor's supervisors, including shop supervisors, and a
list of telephone numbers where the supervisors can be
reached during non-working hours in event of an emergency.
4.5 Protective Coverings.
4.5.1 Prior to starting work on interior spaces, protect
the decks and deck coverings of spaces in which
contract work is to be performed and spaces through
which workers will traverse by covering the decks and
deck coverings with a temporarily fitted heavy vinyl,
plywood or particle board. Securely tape all edges
and joints of the protective covering. Maintain the
protective covering in place during the entire
contract period, renewing sections which are damaged
during the contract period. For those decks over
which equipment, valves, piping, or other materials
must be handled, the temporary protective covering
shall be plywood or particle board and shall be of
sufficient thickness to protect the deck from damage
in the event the equipment or materials are dropped.
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4.5.2 Protect all compartments, machinery, equipment,
deckcoverings, furnishings, vent terminals,
insulation, glass, cables, piping systems, coatings,
structures, and other ship components from damage and
from entry of dust, dirt, grit, sand, and other
foreign particles.
4.5.3 Whenever abrasive blasting or other operations which
create atmospheric contamination are performed on or
near the ship, or which could otherwise allow
airborne contaminates to collect on or in the ship,
the Contractor shall plug, wrap, blank, cover, or
mask all openings to prevent entry of the
contaminates into the ship. Install industrial foam
filter material on the intake and exhaust end of
ventilation systems which will be in use. Renew the
filter materials when air flow becomes restricted.
Whenever abrasive blasting is performed inside the
ship, blast materials shall be confined to the
compartment being blasted.
4.5.4 All damage and contamination resulting from failure
to provide adequate protection shall be repaired and
cleaned tore-establish the condition which existed at
the start of the work.
4.5.5 After completion of all other work, remove and
dispose of all protective coverings.
4.6 Restricted Access. Access by workers to the ship's
compartments shall be restricted to those in which work is
being performed or through which passage is necessary to
reach the worksite. Only one reasonable path through the
ship shall be authorized for each work site. The COR shall
designate those paths authorized for passage by workers.
All other compartments shall be considered off-limits to
workers.
4.7 Daily Clean-up.
4.7.1 Clean-up and remove from the ship all dirt, debris,
scrap, and other materials incident to Contractor's
work at the end of each work day. The work site shall
be left "broom-clean".
4.7.2 Whenever abrasive blasting or other operations on or
near the ship causes collection of blasting residue
or other foreign particles to collect on exterior
decks of the ship, the Contractor shall vacuum or
sweep the decks to remove the residue and particles
prior to the end of the day on which the
contamination occurred. Do not wash the residue or
particles through the ship's deck drains unless
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specifically authorized by the COR.
4.8 Disruption of Ship's Systems.
4.8.1 Except as otherwise authorized, none of the ship's
fire main, electrical, steam, heating, potable water,
drainage, or other systems which are vital to crew
safety or comfort shall be shut off or disrupted. If
necessary to shut off or disrupt any of the systems
to perform contract work, the Contractor shall submit
a written Condition Report to the COR requesting
authorization. The COR must receive the Condition
Report at least 4 hours in advance of the desired
disruption.
4.8.2 Disruptions to the piping and electrical systems,
when necessary, shall be scheduled between the hours
of 10:00pm and 06:00am. Disruptions shall be limited
to 4-hour intervals. If the required work will need a
longer interval, temporary bypass hoses, blank
flanges, or piping shall be installed to keep the
system in operation.
4.8.3 For purposes of this specification, a "disruption"
occurs whenever a large section of a system will be
unusable. If the only section of the system affected
is that on which work is being performed and the
remainder of the system can be operated, a
"disruption" has not occurred and the requirements of
this paragraph do not apply.
4.9 Work Hours. At the beginning of the repair period, the
Contractor shall advise the COR in writing of the planned
regular work day schedule. In the event the Contractor
desires to work at times other than those previously
scheduled, notify the COR at least 4 hours prior to the end
of the scheduled workday preceding the unscheduled work
time. If previously unscheduled work is to be performed on
a weekend or federal holiday, the COR must be notified
prior to 9:00am on the last regular work day before the
unscheduled work.
4.1U Local Policies and Directives. While Contractor personnel,
including those of subcontractors, are on the ship or on
other government facilities, they shall comply with all
policies and directives issued by the Master, Commanding
Officer, or Director of the ship or facility.
4.11 Safety Requirements.
4.11.1 Safety Plan. Prior to starting work on the ship,
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prepare and provide to the COR two copies of a
written Safety Plan. As a minimum, the Safety Plan
shall contain the following:
a. Procedures for obtaining and posting of gas free
certificates.
b. Designation of the certified Marine Chemists
authorized to issue gas free certificates.
c. A copy of Department of Labor Form OSHA
73,"Designation of Competent Person" containing
names of persons designated as a "Competent
Person".
d. Procedures to be followed should any disruption
occur to a temporary service or ship's system
which affects the safety of the ship or
personnel.
e. Description of the Contractor's training program
for firewatch standers.
f. Description of the procedures to be followed
prior to performing any hot work, including the
procedures to be followed to ensure the presence
of a properly outfitted firewatch stander.
g. Description of the duties and responsibilities
related to fire prevention of personnel
performing hot work.
h. Methods of rigging hoses, welding leads, and
temporary lighting to avoid restricting escape
passages and to minimize tripping and other
safety hazards.
i. Whenever the work is being performed at the
Contractor's facility, include a detail
description of the fire protection system which
will be in effect during the contract. Include
the method for reporting fires, the shipyard
fire-fighting facilities, equipment, and
organization, the procedures for maintaining
clear fire lanes in the shipyard and on the
piers, and the nearest municipal fire-fighting
organization. Also the shipyard organizational
responsibilities for reporting to the scene of a
fire for purpose of moving equipment, cutting
accesses, operating fire pumps, and securing or
providing temporary services shall be described
and assigned for all shifts.
j. An inventory listing of and copies of material
safety data sheets (MSDS) for all hazardous
chemicals covered by 29 CFR 1910.1200 which will
be brought onto the ship or which government
personnel may be exposed to under normal
conditions or in a foreseeable emergency.
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k. Procedures to be followed for cleanup should a
spill occur of a hazardous chemical.
1. Other safety procedures as required by the
contractor OSHA regulations.
4.11.2 Gas Free Certification.
a. The Contractor shall be responsible for
certifying that a safe atmosphere exists in and
about a compartment prior to the commencement of
any work. Whenever compartments must be gas free
to meet state and federal regulations, the
Contractor shall pump down, open, remove sludge,
clean, wipe, ventilate and take all other action
required to make the compartments safe for the
work to be performed. When requested by the
Contractor, and to the extent empty tank space is
available, EPA will shift fuel as required to
facilitate gas free requirements. If off-loading
of fuel oil is necessary because of insufficient
empty tank space, the Contractor shall off-load
the fuel.
b. Copies of gas free certificates, issued by a
Marine Chemist certified by the National Fire
Protection Association, shall be posted on the
ship in two locations designated by the COR.
Follow-up inspections by the Contractor's
Competent Person shall also be documented at the
same two locations.
c. The Contractor shall be responsible for
identifying the compartments which require gas
free certification. Specific requirements for gas
free certification are not normally included in
the detail specifications of any work item.
4.11.3 Fire Watch Standers.
a. Hot work is permitted only when fire watch
standers are provided by the Contractor. A fire
watch stander is required whenever welding, flame
cutting or other hot work is performed where
combustible materials are present within 35 feet;
or where wall or deck openings within a 35-feet
radius expose combustible materials in adjacent
areas; or when combustible materials are adjacent
to the opposite side of metal partitions exposed
to hot work, and could be ignited by conduction
or radiation. In the latter case, a fire watch
stander is required on both sides of the
partition.
b. Each fire watch stander shall be outfitted by the
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Contractor with a fire extinguisher of a suitable
size and type, as determined by the COR.
c. Each fire watch stander shall remain at their
work site for at least 30 minutes after
completion of the hot work. Prior to leaving the
work site, the fire watch stander shan verify
with the worker performing the hot work that no
further hot work will be performed.
d. Insulation, sheathing, or other materials which
limit access to either side of a partition or
structure on which hot work is being performed
shall be considered to be interference, and shall
be removed and restored by the Contractor.
4.11.4 Written Hot Work Notice. Prior to starting hot work
on any job or separate of ship, provide a
written notice to the COR and to a representative
of the ship's Commanding Officer/Master.
a. The notice shall state a description of the work
to be done, the location of the work, the time
hot work will commence, the current gas free
status of the area, and the absence or existence
of combustible material in the vicinity of the
work. If combustible material exists, the notice
shall state the action taken to protect the
material from fire, the provision and assignment
of fire watch standers, and affirmation that
conditions at the work site permit the fire watch
standers to observe all areas where the hot work
constitutes a fire hazard.
b. The notice shall be signed by a supervisor
specifically designated as responsible for
coordination of hot work and fire watch stander
requirements.
^. The notice shall be delivered to the
representative of the ship's Commanding
Officer/Master at least 30 minutes and not more
than 24 hours in advance of commencing the hot
work. Approval of the notice by the COR or the
Commanding Officer/Master's representative is not
required.
d. The notice shall be effective for 24 hours unless
a shorter period is specified, or unless the gas
free status of the work area or system required
stopping the work. A new notice is required if
work is interrupted due to a change in gas free
status.
e. Hot work shall be curtailed whenever loss of fire
fighting capabilities occurs on the ship. Hot
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work shall not be commenced again until the
firefighting capabilities have been restored.
4.11.5 Daily Safety and Housekeeping Inspectior,. ~ joint
safety and housekeeping inspection shall be
conducted daily of all spaces affected by
Contractor work. The inspection shall be conducted
by Contractor's Safety Officer and a designated
representative of the ship's Commanding Officer.
The COR may participate in the inspections. Within
4 hours after completion of the inspection, submit
to the COR a written report of the discrepancies
noted and corrective actions to be taken. Submit a
copy of the inspection report to the ship's
Commanding Officer/Master.
4.11.6 Fire Fighting and Prevention Conference. Within 5
days after arrival of the ship at the Contractor's
facility, conduct a Fire Fighting and Prevention
Conference. [Required only if work is being
performed at the Contractor's facility.] The
purpose is to familiarize the ship's crew with the
Contractor's procedures for fire fighting and
prevention and with the procedures that will be in
use by municipal fire-fighting organizations. The
conference will also familiarize the Contractor and
the municipal fire-fighting organizations with the
ship arrangement, shipboard fire prevention, and
fire fighting systems, equipment and organization.
a. The Contractor shall prepare an agenda which
specifically addresses the following:
1. Fire alarm and response procedures.
ntractor fire-fighting capability and
procedures.
; . Municipal fire-fighting capability and
procedures.
4. Communication system for fire reporting and
control of fire-fighting efforts.
5. Shipboard arrangement, including access
routes, availability of fire-fighting
systems, and communications.
6. Shipboard fire-fighting organization,
systems, drills and equipment.
7. Compatibility of ship, Contractor, and
municipal fire-fighting equipment.
b. The exact time and location of the conference
will be established at the arrival conference.
4.11.7 Asbestos-Containing Materials (ACM). Existing
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panels, insulation, gaskets, and other materials on
EPA ships and boats may contain asbestos.
a. Unless otherwise indicated, an asbestos survey
has been conducted for each EPA ship. A Survey
Report has been prepared which identifies the
location of all known asbestos-containing
materials on the ship. A copy of the Survey
Report will be made available for review by
prospective bidders.
b. Within 24 hours after commencement of the
contract performance period, conduct an
inspection of each work site that will involve a
demolition or renovation operation as defined and
required by reference 2.e.
c. The inspection shall be conducted by an ACM
Project Manager who is experienced in
administration and supervision of asbestos
abatement projects, including ACM identification,
work practices, protective measures, and disposal
procedures. The ACM Project Manager shall be a
Qualified Person as defined in and meeting the
requirements of reference 2.f. This person must
have completed a course at an EPA Training Center
or an equivalent certified course and must have a
minimum of two years on-the-job training in
asbestos abatement procedures.
d. Within 24 hours after the inspection(s), the
project manager shall submit a report to the COR
for each worksite. The report shall be submitted
using the form shown in Appendix A of reference
2.g. A contractor-generated form may be
substituted if it provides all the information
shown in Appendix A of reference 2.g.
e. Tne contractor shall be responsible for all
removal, handling, repair, and disposal of all
ACM that are identified as ACM in the applicable
Survey Report, and that is necessary to perform
required contract work. Except as otherwise
specified, the removal, handling, repair, or
disposal of any ACM which is not identified in
the applicable Survey Report will be subject of a
contract modification.
f. All work involving removal handling, repair, or
disposal, and all other activities related to
asbestos-containing materials (ACM) shall be
accomplished in accordance with reference 2.g.
4.11.8 Hazardous Materials.
a. The Contractor is responsible for compliance with
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all local, state, and federal regulations, laws,
and ordinances regarding handling and use of
hazardous materials.
b. Each EPA ship maintains a current inventory and
MSDS's for all hazardous chemicals carried
onboard the ship. A copy of the inventory and
MSDS's will be provided by the COR to the
contractor within two work days after receipt of
a writtenrequest.
c. The Contractor shall provide to the COR an
inventory listing of and copies of MSDS's for all
hazardous materials which will be brought onto
the ship. The inventory listing and MSDS shall be
provided at least 24 hours in advance of any
hazardous material being brought onto the ship.
d. The Contractor shall remove all hazardous
materials used and shall properly dispose of all
hazardous waste produced during the performance
of work under the contract.
4.11.9 Miscellaneous Requirements.
a. Oxygen, acetylene, and gas supply manifold
systems shall be located off the ship and have a
shutoff valve to the gas supply located on the
dock. The shutoff shall be in addition to the
master shutoff valve at the inlet to each
portable outlet header.
b. Material brought onto the ship shall be stored
until used in areas which do not interfere with
access to fire-fighting equipment or personnel
access. Crating and packing shall be removed
prior to bringing the equipment or material
aboard the ship, unless needed to protect the
equipment or material from damage during
handling. In that case, the crating and packing
shall be removed from the equipment or material,
and shall be removed from the ship, immediately
after being brought aboard.
-. Rigging of hoses, welding leads, and temporary
lights shall be kept clear of the decks on
temporary "trees" or brackets and be arranged so
as to minimize tripping and other safety hazards.
Passageways shall be kept as clear of
obstructions as possible.
4.12 Government Property.
4.12.1 Receiving.
a. Provide to the COR a list of names and signatures
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of all persons authorized to receive and account
for Government-Furnished Materials (GEM).
b. When GEM is shipped directly to the Contractor's
facility, provide one signed copy of the shipping
document and one copy of the Bill of Lading
within 24 hours after receipt.
c. Inspect all GEM immediately upon receipt to
verify conformance with shipping document's
description and requirements and to identify all
shipping damage. Also inspect all GEM to verify
that the GEM received conforms to the quantities
and description stated in the detail
specification item for which the property will be
used. Within 24 hours after receipt, submit are
port to the COR of all discrepancies noted during
the inspection.
d. Until used on the work site, properly store the
property as needed to safeguard against damage,
loss, or misuse. Maintain an inventory of the
property which identifies the person receiving
and the person releasing the material. A record
must be maintained at all times of the person
having custody of the material.
4.12.2 Disposition.
a. Scrap. Whenever thp detail specifications
indicates that removed materials are to be
scrapped or properly disposed of, title to the
property is hereby transferred to the Contractor
for disposal or scraping. If the material has any
monetary value, the Contractor shall reflect the
value in the price bid for the applicable work.
b. Salvage. All other materials removed from the
ship shall be treated as Government Property and
shall be handled as follows:
1. Inventory, identify, and tag all material with
the ship's name, contract number, item number,
and material description.
2. Deliver the material to the location specified
in the detail specification. If not specified,
deliver the material to the location specified
by the COR. Pack, crate, and prepare the
material for shipment. Shipping shall be
F.O.B. origin.
3. Comply with the provisions of FAR Clause
52 .245-1-
4.13 Interferences and Restorations.
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4.13.1 Remove all interferences and obstructions necessary
to complete the required work. This shall include
the disassembly and removal of machinery, piping,
ducts, cable, wiring, insulation, structures, and
anything else which interferes with the proper
accomplishment of work. Except as otherwise
specified, this does not include relocations made
necessary by new installations which physically
prevent an interference from being returned to its
existing location.
4.13.2 Whenever an interference to be removed involves a
structural strength member, temporary supports
shall be provided to compensate for the strength
loss. Whenever watertight integrity is violated by
a removed interference, provide a temporary means
of maintaining watertight integrity, except when
work is actually being performed or the space is
otherwise manned.
4.13.3 Prior to removing any interference, meet with the
COR at the work site to discuss the nature,
condition and extent of interferences to be
removed. Record all damage or deterioration which
exists prior to removal.
4.13.4 Install tags on removed interferences to indicate
the nomenclature of the item, ship, and location to
enable proper reinstallation. Treat all removed
interferences as government furnished property.
Store interferences to protect from damage, loss,
and contamination.
4.13.5 Restore all interferences to their existing
configuration and condition. Install new gaskets
and fasteners. In place of material which is
rendered unsuitable for reinstallation during
removal or storage, provide and install new
~"~.^.erials which are equal in composition, strength,
design, type, and size as existed prior to removal.
insulation, including removable blankets, shall
be considered to be unsuitable for reinstallation
and shall be renewed with new insulation.
..__.6 Material containing asbestos which is removed as a
interference shall not be reinstalled. Instead,
renew the asbestos-containing material with a new
non-asbestos material which provides the same
function and general appearance as that removed.
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4.13.7 Align and conduct strength, tightness, and
operational tests to ensure that the reinstalled
interferences safely perform their normal
functions.
4.13.8 The Contractor shall be responsible for identifying
all interferences involved in accomplishing
required work. Interferences are not normally
identified in the detail specifications of the work
item. Therefore, prospective bidders are encouraged
to perform a site inspection whenever possible
before submitting a bid.
4.13.9 Unless specifically authorized elsewhere, the
components of the following systems shall not be
removed as interferences:
a. Steering system piping.
b. Electric cable which cannot be removed without
cutting.
c. Hydraulic systems.
d. High pressure air systems.
e. Spring hangers.
4.14 Shipboard Storage. No space or compartment on the ship
shall be used for storage by the Contractor of materials
or tools. The materials allowed at the work site shall be
limited to those which will be installed, consumed, or
otherwise used during the work shift in progress. When
needed or required, provide a temporary dockside storage
area to store materials and tools.
4.15 Watertight Integrity. Maintain or restore the watertight
integrity of the ship's watertight bulkheads, decks, and
hull by installing stuffing tubes, welded bulkhead and
deck penetrations, multi-cable transits, couplings, and
kick pipes as appropriate. All materials and installation
details shall be same as the nearest similar existing
penetrations.
4.1b Removals.
4.16.1 Whenever removal of equipment or machinery is
specified, but reinstallation is not specified, the
Contractor shall remove all related electric
cables, brackets, foundations, and piping. Removal
of cables shall be to the nearest circuit breaker
or terminal not needed for operation of other
equipment or machinery. Removal of piping shall
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include all related piping not used by other
systems or equipment. Install pipe caps as needed
to maintain remaining piping tight.
4.16.2 Whenever removal of piping or cables involve
penetration through bulkheads, decks, hull plating
or other watertight boundaries, crop out the
penetration and install an insert plate of same
thickness as the adjacent plating. Insert plates
shall be a minimum of 6-inch diameters.
4.17 Structural Access Openings.
4.17.1 The Contractor may, with prior approval, cut access
openings in ship's structure if required to perform
work. Such openings shall be limited to those which
are essential for access to otherwise inaccessible
areas or which greatly improve accessibility for
removals or installations.
4.17.2 Prior to making any access opening in ship's
structure, submit to the COR a sketch of the
proposed opening, showing the location and
dimensions of the proposed access cut, adjacent
framing members, nearby penetrations, and
scantlings of the structure. Generous radii shall
be provided at all corners. Also include a
description of the eventual restoration
configuration, with material and welding details,
and a narrative justification for cutting the
opening. Submittal of the sketch does not insure
unal the COR will authorize the cut as proposed.
The Contractor shall proceed with the access cut
only alter return by the COR of a signed copy of
the sketch.
4.17.3 Restore access openings to existing configuration
and condition. Perform a liquid-penetrant or
magnetic particle inspection of the root pass and
final pass of all welds in watertight structure,
including decks, bulkheads, shell plate, and
frames, at or below the main deck level. The
inspections shall be witnessed by the COR.
4.18 Brackets and Supports. All pipe, cables, ducts, furniture,
equipment, machinery installed by the Contractor shall be
bracketed, supported, and secured so as to carry the
weight, prevent vibration, and withstand inertia forces
resulting from rolling and pitching of the ship.
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4.19 Gaskets, Packing, and Seals. Whenever the Contractor
performs work which disturbs existing gaskets, packing, or
seals, new gaskets, packing, and seals of same material as
existing shall be installed, except use 3/16-inch thick
cork rubber impregnated gasket material conforming to MIL-
C-6183, Type I, Class 1, Grade C for all fuel oil tank
manhole covers and fuel oil service piping.
4.20 Manufacturer's Representative.
4.20.1 The services of a manufacturer's representative is
required only when specified in other
specifications or procurement documents. The
services of the representative shall be provided by
the Contractor unless otherwise stated in the other
specifications or procurement documents.
4.20.2 The manufacturer's representative shall be
specially trained by the manuiacuurer of the
equipment or material and shall be certified by the
manufacturer as authorized to represent the
manufacturer in performing the prescribed tasks. If
requested by the COR, provide written documentation
from the manufacturer attesting that the
representative is authorized to represent the
manufacturer.
4.20.3 The representative shall be considered to be an on-
site technical consultant to provide technical
advice to the Contractor and the COR. When
specified, the representative is also required to
take measurements and conduct inspections. However,
nothing herein shall be construed as relieving the
Contractor of the responsibility to satisfactorily
perform all required work.
4.20.4 Unless other specifications or procurement
documents specifically state that work is to be
performed "as directed by the manufacturer's
representative", the representative shall be
considered to be an advisor, and the Contractor may
deviate from the representative's guidance whenever
necessary to achieve satisfactory work, provided
that the COR accepts the proposed deviation. If the
COR refuses to allow the proposed deviation, the
Contractor must proceed as recommended by the
representative, but in this instance only, the
Contractor will be relieved of responsibility for
any subsequent rework which can be conclusively
shown to have been caused by following the
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representative's guidance.
4.20.5 Prior to proceeding with work which deviates from
the representative's guidance, submit a Condition
Report to the COR which outlines the guidance
provided and the reasons for the proposed
deviation. Proceed with the deviation only after
the COR has reviewed the Condition Report and
accepted the proposed deviation. Whenever the
Contractor deviates from the representative's
guidance, any and all increased costs resulting
from the deviation shall be borne by the
Contractor.
4.20.6 Whenever the manufacturer's representative is
required to be "on-site", the representative shall
be at the work site during all times that work is
being performed.
4.20.7 The Contractor shall obtain from each
manufacturer's representative a detail service
report which outlines all inspections,
observations, and recommendations provided by the
representative. If measurements were taken by the
representative, a record of the measurements shall
be included in the report. Submit a copy of the
service report to the COR prior to completion of
the contract.
4.21 Welding and Allied Processes.
4.21.1 All welding, brazing, and allied processes shall be
in accordance with the requirements and
recommendations of references 2.a and 2.b.
4.21.2 While the ship is water-borne, welding shall be
permitted only when welding leads are properly
grounded. Welding machines and other welding power
sources shall have both cables connected only to
Lhe ship where welding is done. The return ground
cable shall never be grounded to anything but the
ship it is servicing. All welding cables shall be
fully insulated and not be permitted to drop
overboard into the water. The total cross-sectional
areas of the return ground cable shall be at least
one million circular mils per 1,000 amperes per 100
feet, but not less than 85,000 circular mils. The
ground cable shall be securely fastened to
grounding plates or to an integral part of the
18
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EPA-000-1
March 2008
ship, with contact areas thoroughly cleaned to bare
metal.
4.21.3 When welding on equipment, machinery, pressure
vessels, or piping, the return ground cable to the
welding machine shall be connected in the immediate
vicinity (as close as practical) of the work to
ensure that current does not flow through bearings,
pipe hangers or other areas where arcing or high
resistance paths exist.
4.22 Painting.
4.22.1 Prior to applying any paint or coatings, the
Contractor shall verify to the COR that all
surfaces have been properly prepared and that
weather conditions are suitable for painting.
4.22.2 Paint shall be applied only when the following
conditions exist and can be maintained until the
paint has cured:
a. Apply paint only to dry surfaces and when there
is no chance of precipitation until after the
paint has cured. The temperature of the surface
to be painted shall be at least 5 degrees
Fahrenheit above the dew point. The dew point can
be presumed to be satisfactory if a thin, clearly
defined film of water applied to the cleaned
surface with a damp cloth evaporates within 15
minutes. Otherwise, the dew point shall be
measured prior to painting by taking the dry-bulb
temperature of the surface and the wet-bulb
temperature at the jobsite.
b. The air temperature and surface temperature must
both be a minimum of 45 degrees Fahrenheit at all
times, unless a lower temperature is specifically
authorized by the paint manufacturer's printed
instructions.
c. Painting is permitted only when the humidity is
less than 95 percent.
a. In the event the Contractor desires or must
proceed with painting when the existing weather
conditions do not meet the above specified
conditions, the Contractor shall erect a cover
over the surfaces to be painted and shall heat
the surfaces and the surrounding air to establish
the required conditions. The conditions shall be
maintained until the paint has fully cured.
19
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EPA-000-1
March 2008
4.22.3 Restore all existing coating systems which are
damaged during performance of work. The new coating
system shall be same as existing. New materials
shall be painted only if so specified in the detail
specifications or other procurement document.
4.22.4 Surface preparation and paint application shall be
in accordance with applicable EPA Standard
Specifications. In event no applicable EPA Standard
Specification exists, comply with the paint
manufacturers' printed recommendations and
instructions for all aspects of surface
preparation, and handling, mixing, and application
of paint materials.
4.22.5 Surface preparation and painting of shell plating
and frames below the Load Waterline shall be
accomplished only while the ship is in drydock,
unless otherwise and specifically authorized.
4.23 Electrical. All requirements and recommendations of
references 2.c and 2.d shall be followed in the selection
and installation of electrical cables, equipment, and
machinery.
4.24 Piping.
4.24.1 Materials for new installations and new materials
required for replacement of existing piping shall
comply with the requirements and recommendations of
reference 2.b. and MIL-STD-777. In the event a
conflict between reference 2.b and MIL-STD-777, the
more specific and restrictive shall take
precedence.
4.24.2 wnen renewing existing piping, new piping shall be
same material, shall be installed in same
configuration, and shall be installed using the
same methods and details as the existing piping,
unless otherwise specified.
4.25 Tests and Inspections.
t least four hours, but not more than 24 hours, in
advance of conducting each required test and
inspection, notify the COR in order to allow the
COR the opportunity to witness, or to arrange for
another EPA representative to witness, the tests
and inspections. If the COR or other EPA
representative is not present at the scheduled time
of the test or inspection, and if the required 4-
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EPA-000-1
March 2008
hour advance notification was furnished to the COR,
the Contractor may proceed with the test or
inspection.
4.25.2 All tests and inspections shall be witnessed by the
Contractor's supervisor responsible for the work. A
Condition Report (See 4.1) shall be prepared to
document the results of all tests and inspections.
4.25.3 In the event a required test or inspection will be
performed at a location other than the ship or the
Contractor's facility, the Contractor shall provide
round-trip transportation for the COR to and from
the inspection site.
4.25.4 To the extent possible, all tests and inspections
shall be scheduled during the normal weekday work
shift. Tests and inspections may be scheduled for
other times only when necessary to avoid a delay in
the contract completion. When necessary to schedule
a test or inspection after the normal dayshift or
on a weekend, the COR shall be notified of the test
or inspection at least four hours before the end of
the last preceding regular work shift.
4.25.5 Perform an operational test of all newly installed,
overhauled, and repaired equipment to demonstrate
proper operation. Shipboard equipment will be
operated by the ship's crew.
4.25.6 Nondestructive tests (NDT) are required only to the
extent specified in other specifications or
procurement documents. When NDT is required, comply
with MIL-STD-271F, including the requirements for
qualification of NDT personnel, procedures, and
equipment. For purposes of this requirement, NDT is
defined as the following types of test methods:
a. Radiography (RT)
b. Magnetic Particle (MT)
c. Liquid Penetrant (PT)
d. Ultrasonic (UT)
e. Eddy Current (ET)
4.25.7 Workers performing NDT shall be certified as Level
two craftsmen by the American Society for Non-
Destructive Testing in accordance with Recommended
Practice No. SNT TC-1A. Copies of the worker's
certificate shall be provided upon request to the
COR.
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EPA-000-1
March 2008
4.25.8 NDT inspection acceptance standards shall be
asspecified in MIL-STD-2035(SH).
4.25.9 Whenever UT methods are specified for
thicknessgaging, the following procedures and
requirements apply:
a. Prepare the steel surfaces as required to obtain
accurate UT thickness readings. After readings
have been taken, restore coating systems to that
which existed before the surfaces were prepared.
b. The results of the UT thickness gaging shall be
recorded as followr:
1. Prepare a table which lists for each gage
reading the location, actual thickness,
original thickness, percentage of wastage, and
recommendations(if any).
2. Prepare schematic diagrams of the shell
plating, decks, bulkheads, and other
structural members which reflects the
approximate location of each reading and the
actual reading obtained at each location.
c. Submit 3 copies of the table and diagrams to the
.
d. Except for removal and restoration of coatings,
or unless otherwise specified in the Detail
Specifications, removal and restoration of deck
coverings, insulation, and other interferences
are not required in order to take UT readings.
4.25.10 When ever a "hose test" is specified, conduct the
test by directing a 50-psig stream of water from a
1-1/2 inch fire hose through an all purpose nozzle
at a distance of not more than 10 feet from the
surface being tested. Direct the stream of water in
a manner most likely to disclose a leak and inspect
thp opposite side of the surface for leaks.
4.25.11 When ever an "air test" is required, conduct the
Lest by sealing all vents and applying 2 psig air
pressure to the specified tank or compartment.
After the 2 psig pressure is attained, disconnect
the air supply and monitor the pressure in the tank
or compartment with a calibrated pressure gage for
lOminutes. If the pressure drops below 1.9 psig
during the 10 minute period, increase the pressure
to 2 psig and inspect for leaks by applying soapy
water to all new welds, and to all manhole covers
22
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EPA-000-1
March 2008
of the tank or compartment. After the test, insure
that all vents are unsealed.
4.26 Fuel Oil and Lube Oil Offloading.
4.26.1 Whenever the Contractor is required to or elects to
offload fuel oil or lube oil from the ship, the oil
shall be pumped to and stored in clean moisture-
free storage tanks. Meter the oils with a
calibrated meter during offloading and during
return. Take test samples during offloading and
during return, and have the test samples analyzed
by a lab for water and impurities to verify that
the oils were not contaminated while in the
Contractor's possession. Provide copies of lab
reports to the COR.
4.26.2 After all work which necessitated the oil's removal
has been completed, return the oil to the ship. In
lieu of storing the oil, the Contractor may accept
title and responsibility for disposal of the oil
and provide an equal amount of new clean oil, same
as that removed. Test samples are required, even if
this option is exercised by the Contractor.
4.27 Disposal of Water. Whenever work requires that equipment,
machinery, piping, or tanks be drained of water, the
Contractor shall be responsible for draining and proper
disposal of the water. If the Contractor drains the water
into the ship's bilges, the Contractor shall pump all
water from the applicable bilges into dockside tanks and
properly dispose of the water, including the water that
existed prior to and the water that accummulates between
the time the equipment, machinery, piping or tanks were
drained and the time the bilges have been pumped dry by
the Contractor.
4.28 Work at Government Facilities. The following requirements
and provisions apply only when the Contractor performs
work at a Government shore facility.
4.28.1 Restrictions.
a. The Contractor will not be permitted to use the
Government facility's waste disposal containers for
disposal of scrap, waste or any other materials. If
the Contractor desires to bring a waste disposal
container onto the facility, the container shall not
be larger than eight cubic yards capacity. Only one
container will be permitted.
b. Contract work on more than one ship may be in
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EPA-000-1
March 2008
progress concurrently at the facility. Therefore,
pier space and parking space may be scarce. Ample
pier space will be provided for the Contractor to
perform the required contract work. However, the
Government reserves the right to prohibit or limit
the number of vehicles permitted onto the facility
and to specify the permitted parking locations. All
vehicles being brought onto the facility will be
required to apply for a vehicle paoo.
4.28.2 Government-Furnished Services.
a. The Government will provide adequate electric service
either on the ship or on the dock for the Contractor
to operate equipment and tools necessary to
accomplish the required work. The Contractor shall be
responsible for making all electrical connections and
for providing all cables, plug, adapters, and other
materials for making the connections.
b. The Government will provide water service to the
Contractor for use in performing the required work.
The service will be limited to that which can be
provided by the Government's installed equipment and
does not include providing of any hoses or fittings.
c. If the ship on which the work is being performed has
operable installed cranes, the ship will provide
crane service to assist the Contractor in lifting
materials to and from the ship during the first three
days of the contract performance period. The service
provided will be limited to the capacity and reach of
the ship's crane(s) in its existing condition. The
crane will be operated by ship's personnel. Crane
service will be limited to the handling of materials
which exceed 100 pounds and which cannot be easily
carried by the workers. The Contractor shall
coordinate and schedule the crane service to minimize
the number of lifts required. At least four hours
advance notice shall be given to the COR of the need
for crane service.
4.29 Water Depths and Height Restrictions. Whenever the
contract work is to be performed at the Contractor's
facility, the government is responsible for transferring
the ship to the facility, unless otherwise specified. In
addition to the contract clauses included in the bid
solicitation, the following restrictions and requirements
apply.
4.29.1 At no time will the ship be moored at any dock or
transit any waterway which has a water depth less
24
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EPA-000-1
March 2008
than that required to provide a minimum clearance
of one foot under the lowest underwater projection.
4.29.2 The minimum liquid load, drafts and displacement of
the ship at which the government intends to transit
and arrive at the Contractor's facility will
normally be provided in the detail specifications.
Also included will be information concerning any
changes in the ship's liquid load which the
Contractor will be permitted to make in order to
meet the minimum underwater clearance requirements.
4.29.3 At no time will the ship transit a waterway which
has non-opening bridge or other overhead structure
that would cause less than one-foot clearance over
the ship's highest projection. In order to permit
passage of the ship under bridges or other overhead
structures in the waterway, the government will
lower masts which have hinged connections for that
purpose. However, the government will not remove,
and will not permit the Contractor to remove, any
part of the ship's structure or equipment for the
purpose of providing the required overhead
clearance.
4.30 Ship's Moorings. Whenever the contract requires work to be
performed at the contractor's facility, the contractor
shall provide adequate pier or dock space acceptable to
the Contracting Officer for safely mooring the ship. The
following requirements and restrictions apply:
4.30.1 The facilities and services shall be sufficient to
permit the contractor to comply with all other
requirements of the contract.
4.30.2 Contract award is based, in part, on information
provided by the contractor during the pre-award
survey regarding the pier or dock facilities which
will be used to moor the ship. Unless specifically
approved in writing by the COR, the ship shall not
be moored at any pier or dock space other than
those proposed during the pre-award survey.
4.30.3 Shifting of the ship from one mooring berth to
another causes disruption of services to the ship
and interferes with work and schedules of the crew.
Unless specifically approved by the Contracting
Officer, no more than one mooring shift (drydocking
and refloating excluded) of the ship shall be made
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EPA-000-1
March 2008
during the contract period.
a. When shifting of the ship is required, the COR
shall be given a minimum of three days advance
notice of the proposed shift.
b. Except when drydocking and refloating the ship,
all shifting of the ship shall be performed only
during regular workdays and hours.
4.30.4 All mooring spaces to be used by the ship shall be
under the complete and legal control of the
contractor. If the contractor proposed to use any
mooring space which is not owned by the contractor,
a legally binding lease or agreement must be signed
by the owner which clearly gives the contractor
complete control of the mooring for the entire
period of the contract, including any time
extensions which may be approved by the Contracting
Officer. A copy of the agreement, will be required
to be submitted as part of the pre-award survey.
4.31 Disassembly and Inspections. Whenever equipment,
machinery, systems, or other system components are
required to be disassembled, opened or overhauled, the
contractor shall complete all disassembling and
inspections during the first 25-percent of the work
performance period. All tanks required to be opened shall
also be opened and gas-freed during the first 25-percent
of the work performance period. No time extension of the
work performance period will be granted for delays caused
by the contractor's failure to comply with this 25-percent
time requirement.
5. NOTES.
5.1 The requirements and provisions of this specification are
additions to or amplification of the requirements and
provisions set forth in other specifications,
solicitation, or procurement documents. In the event a
conflict should occur, the requirements of the other
documents take precedence over those contained herein.
26
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EPA-000-2
SUPERSEDING
NOAA MO A
AMC-000-2B
March 2008
U.S. Environmental Protection Agency
Mid-Continent Ecology Division
STANDARD SPECIFICATION EPA-000-2
TEMPORARY SERVICES AT CONTRACTOR FACILITIES
1. SCOPE. This specification contains the general requirements for temporary services to be
provided to EPA ships while at a Contractor's facility.
2. REFERENCES.
None
3. REQUIREMENTS.
3.1 General.
3.1.1 Except as otherwise reqi ' pi -^ all Incii'..' ¦ ¦ ¦¦ y \ ices required by this
specification for the enti .¦ ¦¦ noo : .¦ :s !he o.itractor's facility.
3.1.2 Provide all cables, hoses-. •' '--us. r •• needed to provide the services to
the ship. After completion of all other contract work and immediately before the
ship departs the Contractor's facility, disconnect all temporary services and remove
all related cables, hoses, fittings, and equipment.
3.1.3 Make all connections and provide all services within two hours after the ship arrives
at the facility. The services are to be disconnected only when necessary to shift the
ship or upon satisfactory completion of all authorized items of the contract. When
the ship is shifted, drydocked, or refloated, the services are to be restored for normal
use within one hour after completion of the shifting, dry docking, or refloating
operation.
3.1.4 Whenever water is provided to the ship from a municipal potable water system,
comply with local ordinances and the U.S. Public Health Service regulations
regarding use of check valves and other automatic closure devices to prevent
contamination of the municipal water source.
3.1.5 Hoses to be used for potable water or steam service shall not have been previously
used for any other purpose. Prior to connecting to the ship's system, thoroughly
¦" .¦ iic hoses with water from the municipal water system.
3.1.6 Whenc\ e:' vvater, air or steam service is required, provide a pressure regulator and a
; gage at the deck connection to monitor and regulate the pressure.
3.2 Gangways. Provide two safe gangways or brows for easy access to the ship. One shall be
located near the forward end and one shall be located near the aft end of the ship.
Whenever the ship is in drydock or on a railway, the gangways or brows shall be located on
opposite sides of the ship. The gangways and brows shall be of good sound construction,
with cross-member cleats or abrasive non-slip walk surfaces, double lifelines or handrails
on each side, and a safety net underneath. If the shore end of the brows or gangways
1
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terminate above the level of the wharf, pier, or dock normally used for traffic, steps with
handrails shall be provided. Access to the ship shall be well lighted during periods of
darkness. Provide safety nets extending outward six feet on each side of each gangway.
3.3 Camels and Fenders. Provide a camel or fender system to prevent the ship's sides from
chafing against the wharf or pier while the ship is moored at the Contractor's facility. When
moving the ship with tugs, ensure that adequate fenders are used to ¦ ¦ .¦¦¦. UnMing of the
ship's hull against the tug. All damage to the ship's hull structure an ' ¦ unu sv items
which occurs due to lack of adequate fenders shall be repaired bv contractor. No other
ship or barge shall be moored alongside the ship.
3.4 Electric Power. Furnish necessary flexible shore tie cable, with compatible terminal
connections, and provide electrical power to the ship's shore power connection box.
3.5 Potable Water. Provide uncontaminated potable water to the ship's potable water deck
connection as follows:
3.5.1 Water pressure at the connection shall • ->i ho i.-x:niu! r-ot more than 60
pounds-per-square-inch-gage.
3.5.2 Prior to making the hose connection to j.iip, pruv idc lo COR adequate
documentation that the water fully complies with the Safe Drinking Water Act
(SDWA). As a minimum, the documentation must include:
a. A report from a local health authority or an independent testing lab attesting that
the water supply meets safe bacteriological levels.
b. Additional data, attainable from the water supplier, which verifies compliance
with physical, chemical, and aesthetic standards of the SDWA.
3.6 Telephone Service.
3.6.1 Shall provide and install private line telephone in location designated in the detail
specificatioi i item. II not designate'' in hie detail specification item, the telephone
shall be located as specified by the COR.
3.6.2 Telephones shall be push huiu-i. . -n lone.
3.6.3 The telephones are n-ji bo on a party line and are to be connected such that
outside numbers can be dialed or received on any day at any time.
3.6.4 Telephone service shall be provided for making local calls, 800 toll free calls and
long distance calling card calls (using government Sprint calling cards). In the event
that the telephones are used to make long distance toll calls, the contractor shall
prepare a separate invoice, including an itemized list of the long distance toll calls.
Submit the invoice to the ship for payment at the completion of the contract period.
3.7 Fax Machine. Provide a properly operating Fax machine with operational instructions, on a
u ¦ ¦ ¦ ¦ ¦ i (ol- phone service in the dock side office space or onboard the ship as
spot' .¦¦¦ -y ;!io COR. The telephone service shall be private direct line service and shall
¦¦iormii *nu ci'stance (using government Sprint calling cards) calls. Telephone service for
the fax machine is in additional to the telephone service required above.
3.8 Sanitary and Cooling Water. While the ship is drydocked, provide ample fresh or salt water
for proper operation of the ship's sanitary, refrigeration, and air conditioning cooling
systems.
3.9 Steam. Whenever required by the detail specification item, provide steam to the ships deck
connection in the amount specified.
2
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3.10 Sewage and Turbid Water Disposal. Accept and properly dispose of effluent sewage and
turbid water from the ship's deck connection or overboard discharge. The ship's installed
pumps will be used to pump the sewage and turbid water to the deck connection.
3.11 Garbage and Refuse. Provide containers on the ship in sizes and quantities required for
convenient, sanitary disposal of garbage and refuse by the ship's ere . ¦. : ¦' ¦ ¦ vqimte deck
space is not available on the ship and if authorized by the COR, the ¦ j'hkts shall be
located off the ship within 20 feet of the gangway specified by the COR. Empty and clean
the containers daily to prevent them from becoming a health hazard.
3.12 Toilet Facilities. Whenever the detail specifications specifies that temporary toilet facilities
are required or whenever the Contractor must secure the ship's toilet facilities, adequate
temporary toilet facilities must be provided for EPA use.
3.12.1 Provide one temporary toilet for each 25 persons, or part thereof, in the ship's crew.
3.12.2 When the ship is in a drydock or marine railway, or the ship is moored dock side,
the toilet(s) must be within 200 feet of ..ic ship s gangway.
3.12.3 Portable chemical toilets are acceptable, provided the Contractor empties and cleans
them regularly.
3.13 Fire Alarm System.
3.13.1 Availability of a fire ala • ' sysu-m nun . by ship's
representative). The fire ¦ ¦ "in s : he ornsiiu..-.- .¦d :• signal directly to a central
station service, a remote .¦ ¦ '*w se :• nuMi'.-.-'iptW ;ire department, a shipyard fire
department, or a continu; . man- wMhin the shipyard where trained
operators can take immediate action to transmit an alarm.
3.13.2 The mean . in :-:inmnoi. .¦ ire <' isni*.:nt from within the shipyard shall consist of
a direct electrically supervised circuit to the fire department or manual operation of
a municipal fire alarm box within 50 feet travel distance of the centrally manned
3.13.3 The fire alarm system shall be reliable, use electrically supervised circuits and
provide facilities at the centrally manned location for making daily tests of the
system. Defective or inoperative alarms shall be repaired or replaced immediately.
No hot work will be permitted anywhere on the ship while the alarm system is
inoperative or defective.
3.14 Fire-Fighting Water Supply.
3.14.1 Shoreside means shall be provided to ensure that the emergency water supply can
be connected to the ship's fire main system within 5 minutes or to be used to apply
water on the ship in drydock.
Power for the emergency source shall be independent of the Contractor's normal
.¦ . of .. ectrical power. The emergency source shall be capable of being
;>i'u\ i.''-:d when local utilities are disrupted.
Demonstrate proper operation of the emergency source within 8 hours after the ship
arrives at the Contractor's facility and perform an operational test weekly.
3 .14.2 Provide and maintain an emergency source of fire-fighting water capable of
providing 500 gallons-per-minute at 100 pounds-per-square-inch-gage to the ship's
weather deck within five minutes of loss fire-fighting water pressure at the ship's
fire main. The emergency source shall be completely independent of the source
used to provide water to the fire main system.
3
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3.15 Vehicle Parking Spaces. Provide vehicular parking spaces in the quantity specified in the
detail specification item. The parking spaces shall be inside the Contractor's facility or
within 100 feet of the gate to the Contractor's facility. The spaces may be outside the gate
to the Contractor's facility only if the Contractor has the means to control unauthorized use
of the parking spaces. The parking spaces shall be reserved exclusively for use by EPA
personnel and shall be clearly marked "RESERVED-EPA".
3.16 Dock side Office Space. When required by the detail specifications oiIky p urement
documents, provide dock side office space for exclusive use of EPA personnel in the
quantities specified therein. Office space shall comply with the following:
3.16.1 Each space shall be a minimum of 12 feet by 12 feet and shall be equipped with at
least one 30-inch by 60-inch desk, one 30-inch by 48-inch (minimum) work table,
two chairs, a two-drawer file cabinet, waste paper basket, three double electric 110
VAC outlets (with power connected) evenly spaced around the space, adequate
lighting.
3.16.2 Each office space shall be heated to 68 TV" .',i .-in.1 cooled to 78 degrees
Fahrenheit.
3.16.3 Provide adequate toilet facilities adjacent and adjoining office space. Each
toilet facility shall be provided with at least one water closet and one lavatory.
Provide ample toilet tissue, soap and paper towels.
3.16.4 Provide daily janitorial service to clean the toilet facilities, office spaces and to
empty waste paper baskets.
3.16.5 The office spaces shall b .¦ -mw ¦: -v.-: ;js prodicc. he ship, but in no case
shall the office spaces b.- o Hir- i'wf -vi me shin.
3.17 Security Service. Whenever required by the detail specifications or other procurement
document, provide security guard service during all periods that no contract work is being
performed on the ship. A guard shall inspect all unlocked compartments at least once every
two hours, or part there, while work is not being performed.
3.18 Enui:.. J* oom t'i •. ¦ ( ka;:i;iu. Dm i ng the l'i :rt three days of the repair period, pump and
properly of;;!' ¦ ily water from the engine room bilges. At the completion of all
•;:n i lit.- ¦ ¦ gine room bilges by flushing with a cold freshwater hose wash
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E PA-0 0 0-3
March 2008
SUPERSEDING
AMC-631-2C
AUGUST 1995
U.S. Environmental Protection Agency (USEPA)
Mid-Continent Ecology Division
STANDARD SPECIFICATION EPA-000-3
COATING SYSTEMS FOR STEEL SURFACES
1. SCOPE. This specification contains the general requirements
for surface preparation and application of the coating systems
most frequently used on the steel surfaces of EPA steel ships
and boats.
2. REFERENCES.
(a) SSPC: The Society for Protective Coatings Paint
Application Specification No. 1 (SSPC- , , Field, and
Maintenance Painting" (April 1, 2000)
(b) SSPC: The Society for Protective Coatings Paint
Application Standard No. 2 (SSPC-PA 2), "Measurement of Dry
Coating Thickness with Magnetic Gages" (June 1, 1996)
(c) SSPC: The Society for Protective Coatings Joint Surface
Preparation Standard SSPC-SP 10/NACE No. 2, "Near-White Blast
Cleaning" (September 1, 2000)
(d) SSPC: The Society for Protective Coatings Surface Joint
Surface Preparation Standard SSPC-SP 12/NACE No. 5, "Surface
Preparation and Cleaning of Steel and Other Hard Materials by
High- and Ultrahigh-Pressure Water Jetting Prior to Recoating"
(1995)
(e) SSPC: The Society for Protective Coatings Surface
Preparation Specification No. 3 (SSPC-SP 3), "Power Tool
Cleaning" iNovember 1, 1982 Editorial Changes September 1, 2000)
(f) SSPC: The Society for Protective Coatings Surface
Preparation Specification No. 1 (SSPC-SP 1), "Solvent Cleaning"
(November 1, 1982 Editorial Changes September 1, 2000)
(g) SSPC: The Society for Protective Coatings Surface
Preparation Specification No. 11 (SSPC-SP 11), "Power Tool
Cleaning to Bare Metal" (November 1, 1987 Editorial Changes
September 1, 2000)
(h) SSPC: The Society for Protective Coatings Joint Surface
Preparation Standard SSPC-SP 7/NACE No. 4, "Brush-Off Blast
Cleaning" (September 1, 2000)
Page 1 of 12
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E PA-0 0 0-3
March 2008
3. REQUIREMENTS.
3.1 General Requirements.
3.1.1 All paint application shall applied in compliance with
reference (a) as reinforced and supplemented by this
specification.
3.1.2 Comply with the manufacturers' printed recommendations
and instructions for all aspects of handling, mixing, and
application of the paint materials.
3.1.3 All paint shall be delivered to the jobsite in
original, unopened containers with labels intact. All containers
shall remain unopened until required for use. Each container of
paint shall be clearly marked or labeled to show paint
identification, date of manufacture, batch number, analysis of
contents, identification of all toxic substances, and special
instructions.
3.1.4 Paint shall be used before its shelf life has expired.
If a paint has no stated shelf life or is more than one year old,
the manufacturer must certify in writing that the paint is
suitable for use.
3.1.5 All coating thicknesses are stated in dry film
thickness (DFT). All dry film thickness determinations shall be
performed in accordance with reference (b).
3.1.6 Coatings shall be applied only when the following
conditions are maintained:
a. Apply paint only to dry surfaces and when there is no
chance of precipitation until after the paint has cured. The
steel surface temperature shall be at least five degrees
Fahrenheit above the dew point. The dew point can be presumed to
be satisfactory if a thin, clearly defined film of water applied
to tne cleaned surface with a damp cloth evaporates within 15
minutes. Otherwise, the dew point shall be measured prior to
painting by taking the dry-bulb temperature of the surface and
the wet-bulb temperature at the jobsite.
b. The air temperature and surface temperature must both
be a minimum of 45 degrees Fahrenheit at all times, unless a
lower temperature is specifically authorized by the paint
manufacturer'a printed instructions.
c. Painting is permitted only when the humidity is less
than 95 percent.
d. When paint must be applied in damp or cold weather, the
steel must be painted under cover and the surrounding air and the
steel heated to establish the required conditions. The steel
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shall remain under cover or be protected until dry or until
weather conditions permit its exposure.
3.1.7 Each coat of paint shall be in a proper state of cure
or dryness before the application of the succeeding coat. Paint
shall be considered dry for recoating when an additional coat can
be applied without the development of any detrimental film
irregularities, such as lifting, wrinkling, or loss of adhesion
of the undercoat. The time interval between coating applications
shall be in compliance with the manufacturer's Drinted
instructions.
3.1.8 All paint materials shall be furnished by the
Contractor and shall be applied using spray equipment, unless
otherwise specified. When applying touch-up coatings to small
areas disturbed by other work, brushes and rollers may be used.
3.1.9 Comply with and enforce all safety and environmental
protection regulations relative to removal, disposal, mixing, and
application of paints and other materials.
3.1.10 Mask, tape, cover, and otherwise protect all equipment,
machinery, cables, piping, insulation, glass, furnishings, and
other government materials from damage, overspray and
contamination. Remove and reinstall parts and loose gear as
necessary to avoid damage.
3.1.11 Plug, wrap, blank, cover, or mask all openings as
needed to prevent entry of blast materials into the ship or boat
and to confine blast materials inside the compartment being
sandblasted. Install industrial foam filter materials on the
intake and exhaust of ventilation systems which will be in use.
Renew filter materials when air flow becomes restricted.
3.1.12 When surface preparation and coating of a compartment
or surface is specified, included shall be all plating, frames,
longitudinals, beams, stiffeners, brackets, baffles, and other
structural steel memcers. Steel ladders in tanks, voids, and
cofferdams are also to be included.
3.1.13 Surface preparation and paint application of shell
plating and frames below the Load Waterline shall be accomplished
only while the ship is in drydock, unless otherwise and
specifically authorized.
3.1.14 Where colors are not specified in this specification,
the color for coatings shall be as specified in other procurement
documents or specifications. Where colors are not specified
elsewhere, the colors shall be selected by the COR or other EPA
representative responsible for acceptance of the work.
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3.2 Surface Preparation.
3.2.1 Unless otherwise specified, all steel surfaces shall be
prepared by sandblasting to a "near white" surface in accordance
with reference (c). or prepared by "ultrahigh-pressure water
jetting" to a visual surface preparation condition of WJ-2 in
accordance with reference (d) .
3.2.2 When other procurement documents or specifications
require "power tool clean" surface preparation, the therein
specified steel surfaces shall be prepared in accordance with
reference (e).
3.2.3 When other procurement documents or specifications
require "solvent clean" surface preparation, the therein
specified steel surfaces shall be prepared in accordance with
reference (f) .
3.2.4 When other procurement documents or specifications
require "power tool clean to bare metal" surface preparation, the
therein specified steel surfaces shall be prepared in accordance
with reference (g).
3.2.5 When other procurement documents or specifications
require "brush-off blast cleaning" surface preparation, the
therein specified steel surfaces shall be prepared in accordance
with reference (h).
3.2.6 The surfaces to be painted shall have the specified
surface preparation at the time of application of the paint. If
the surface is degraded or contaminated subsequent to surface
preparation and prior to painting, the surface shall be restored
before paint application.
3.2.7 In order to prevent degradation or contamination of the
prepared surtaces, the first coat of paint shall be applied as
soon as possible after the surfaces have been prepared. The
first coat shall always be applied the same day as surface
preparation is completed. Succeeding coats shall be applied
before contamination of the under surface occurs.
3.2.5 After surface preparation, surfaces shall be brushed
with clean brushes, blown off with compressed air, or cleaned by
vacuum to remove all traces of blast products and dust.
3.2.6 Whenever sandblasting or spray painting is specified
for surface preparation of exterior steel surfaces at a
Government facility, or when applicable regulations and laws
prohibit release of blast materials and paint into the
atmosphere, the surfaces shall be enclosed in a cover adequate to
contain the blast materials and paint.
3.2.7 Cleaning and painting shall be so scheduled that
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detrimental amounts of dust or other contaminants do not fall on
wet, newly-painted surfaces.
3.3 Coating Systems. Following acceptance of the surface
preparation by the COR, apply the coating system specified in
the procurement document or detail specification and defined
below. It is understood that newer coating systems have been and
are being developed that may supercede the defined coating
systems. The contractor may recommend application of these newer
coating systems through the use of a Condition Recort which is
subject to acceptance by the COR.
3.3.1 System STL-1:
a. Apply one coat, 3.0 to 4.0 mils DFT, of self-curing
inorganic zinc silicate, using one of the products listed in
Appendix A.
b. Allow the coating to dry for 24 hours and rinse
with fresh water to remove the white crystallized drying salts.
3.3.2 System STL-2:
a. Coat one: Apply 3.0 to 4.0 mils DFT, self-curing
inorganic zinc silicate, using one of the products listed in
Appendix A. Allow the coat to dry for 24 hours and rinse with
fresh water to remove the white crystallized drying salts.
b. Coat two: Apply a mist tie coat, 0.5 to 1.0 mils
DFT, polyamide-epoxy primer, MIL-P-24441, formula 150 (green).
c. Coat three: While the previous mist tie coat is
still tacky, apply 3.0 to 4.0 mils DFT, of polyamide-epoxy, MIL-
P-24441, formula 150 (green).
d. Coat four: While the previous coat is still tacky,
apply 2.0 to 3.0 mils DFT, of 30-percent modified silicone alkyd
high gloss marine paint, using one of the products listed in
Appendix B.
e. Coat five: Apply 2.0 to 3.0 mils DFT of 30-percent
modified silicone alkyd high gloss marine paint same as previous
. .
3.3.3 System STL-3:
a. Coat one: Apply 2.0 to 4.0 mils DFT, polyamide-
epoxy, MIL-P-24441, formula 150 (green).
b. Coat two: Apply 2.0 to 4.0 mils DFT, polyamide-
epoxy, MIL-P-24441, formula 152 (white).
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c. Coat three: Apply 2.0 to 4.0 mils DFT polyamide-
epoxy, MIL-P-24441, formula 156 (red).
d. The thickness of the total 3-coat system shall not
be less than 8 mils DFT nor more than 12 mils DFT.
e. When applying this system to the entire interior of
tanks, voids, or bilges, apply an additional hand brush (stripe)
coat after coat one and after coat two to weld seams, cutouts,
corners, and butts. Each hand coat shall be unthinned and shall
be a different color than the coat being covered, but may be the
same color as the coat to follow.
3.3.4 System STL-4:
a. Coat one: Apply 2.0 to 4.0 mils DFT, polyamide-
epoxy, MIL-P-24441, formula 150 (gr^~""^ .
b. Coat two: Apply 2.0 to 4.0 mils DFT, polyamide-
epoxy, MIL-P-24441, formula 156 (red).
c. Coat three: Apply 2.0 to 4.0 mils DFT, polyamide-
epoxy, MIL-P-24441, formula 152 (white).
c. The thickness of the total 3-coat system shall not
be less than 8 mils DFT nor more than 12 mils DFT.
e. When using this coating system in potable water
tanks, comply with the following requirements:
1. The total maximum DFT specified above shall
not be exceeded except in isolated areas adjacent to shapes,
frames, and stiffeners. In no case shall the maximum be exceeded
by more than two mils DFT. The isolated areas shall not exceed
two percent of the total area.
2. Insure that no formula substitutions are made.
3. The drying time between coats shall be a
minimum of 48 hours at a minimum temperature of 70 degrees
Fahrenheit. Provide heated air if necessary to maintain the
temperature. Provide sufficient ventilation during the drying
time for continuous flow of air through the tanks with at least
one complete air change every four hours.
4. A minimum of seven calendar days curing time
is required after application of the last coat before filling
tanks wi Lii water. Complete application of the last coat at least
seven days prior to the end of the contract performance period.
5. When applying this system to the entire
interior of tanks, apply an additional hand brush (stripe) coat
after coat one and after coat two to weld seams, cutouts,
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corners, and butts. Each hand coat shall be unthinned and shall
be a different color than the coat being covered, but may be the
same color as the coat to follow.
3.3.5 System STL-5:
a. Coat one: Apply 2.0 to 4.0 mils DFT, polyamide-
epoxy, MIL-P-24441, formula 150 (green).
b. Coat two: Apply 2.0 to 4.0 mils DFT, polyamide-
epoxy, MIL-P-24441, formula 151 (haze grey).
c. Coat three: Apply 2.0 to 4.0 mils DFT polyamide-
epoxy, MIL-P-24441, formula 156 (red) .
d. Coat four: Apply 2.0 to 4.0 mils DFT polyamide-
epoxy, MIL-P-24441, formula 152 (wh^"1"^ .
e. The thickness of the total 4-coat system shall not
be less than 10 mils DFT nor more than 16 mils DFT.
f. When applying this system to the entire interior of
tanks, apply an additional hand brush (stripe) coat after coat
one and after coat two to weld seams, cutouts, corners, and
butts. Each hand coat shall be unthinned and shall be a
different color than the coat being covered, but may be the same
color as the coat to follow.
3.3.6 System STL-6:
a. Coat one: Apply 2.0 to 4.0 mils DFT polyamide-
epoxy, MIL-P-24441, formula 150 (green).
P. Coat two: Apply z.O to 3.0 mils DFT latex fire-
retardant paint, DOD-C-24596, Type I.
r.. Coat thrpe: Same as coat two.
3.3.7 System STL-7:
a. Coat one: Apply 2.0 to 4.0 mils DFT heat resistant
aluminum paint, DOD-P-24555.
b. Coat two: Same as coat one.
3.3.8 System STL-8:
a. Coat one: Apply 3.0 to 4.0 mils DFT, self-curing
inorganic zinc silicate, using one of the products listed in
Appendix A. Allow the coat to dry for 24 hours and rinse with
fresh water to remove the white crystallized drying salts.
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b. Coat two: Apply a mist tie coat, 0.5 to 1.0 mils
DFT, polyamide-epoxy primer, MIL-P-24441, formula 150 (green).
c. Coat three: While the previous mist tie coat is
still tacky, apply 3.0 to 4.0 mils DFT, of polyamide-epoxy, MIL-
P-24441, formula 150 (green).
d. Coat four: While the previous coat is still tacky
apply 5.0 mils minimum DFT, anti-sweat binder, DOD-P-15144,
formula 34.
e. Coat five: While the binder is still tacky, blow
heavy coat of expanded vermiculite, ASTM C-516 onto the surfaces
using compressed air.
f. Coat six: Apply 2.0 to 3.0 mils DFT of latex fire
retardant paint, DOD-C-24596, Type
3.3.9 System STL-9:
a. Coat one: Apply 2.0 to 4.0 mils DFT, polyamide-
epoxy, MIL-P-24441, formula 150 (green).
b. Coat two: Apply 30.0 to 40.0 mils DFT, non-skid
coating, DOD-C-24667, Type T, "¦ +~"¦ ^ r-, Grade A, Class 2.
In the event this coating cannot be obtained, non-skid coating,
MIL-D-24883, Type I may be substituted.
c. Coat one shall be allowed to cure a minimum of 24
hours, but not more than 48 hours, before application of coat
two.
3.3.10 System STL-10:
a. Coat one: Apply 3.0 to 4.0 mils DFT, self-curing
inorganic zinc silicate, using one of the products listed in
Appendix A. Allow the coat to dry for 24 hours and rinse with
fresn water to remove the white crystallized drying salts.
b. Coat two: Apply a mist tie coat, 0.5 to 1.0 mils
DFT, polyamide-epoxy primer, MIL-P-24441, formula 150 (green).
c. Coat three: While the previous mist tie coat is
still tacky, apply 2.0 to 4.0 mils DFT of polyamide-epoxy, MIL-P
24441, formula 150 (green).
d. Coat four: While the previous coat is still tacky
apply 2.u lu 3.0 mils DFT of 30-percent modified silicone alkyd
high gloss marine paint, using one of the products listed in
Appendix B.
e. Coat five: Immediately after applying coat four,
spread a coat of #40-mesh garnet over the coating while it is
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still wet. Completely cover the coating and allow the coating to
dry for eight hours. Then, sweep off and vacuum up the excess
garnet.
f. Coat six: Same as coat four.
3.3.11 System STL-11:
a. Coat one: Apply 4.0 to 8.0 mils DFT of Devoe Bar-
Rust 235.
b. Coat two: Same as coat one. Total thickness of
the two coats shall not be less than 12.0 mils DFT.
4. QUALITY ASSURANCE.
4.1 Certification and Records.
4.1.1 Whenever the surfaces to be prepared and coated
exceeds a total surface area of 10 square-feet, comply with the
following prior to commencing the surface preparation:
a. Prepare and submit to the COR a detail "Paint
Plan" which clearly outlines the complete painting timetable and
procedures, including methods for conducting and documenting
inspections. Also to be included shall be copies of all
applicable manufacturers' printed recommendations, instructions
and product data sheets.
b. The Contractor's paint foreman shall meet with the
COTR to discuss and review the "Paint Plan".
4.1.2 Provide to the rra i-hp following information:
a. Number of gallons of each type paint used.
b. Certification by the Contractor's paint foreman
that the conditions specified in 3.1.5 were maintained during
application and curing of the paint. If measured, wet-bulb
temperature at the jobsite and dry-bulb temperature of the
surface immediately before applying each coat of paint.
c. Date and time of starting and completing each coat
of paint.
a. Complete set of all DFT measurements taken.
4.2 Inspections.
4.2.1 Prior to any sandblasting or painting, conduct an
inspection with the COR of all protective coverings and masking
to insure that the protection is adequate.
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4.2.2 After completion of surface preparation, the COR or
other person designated by the COR shall inspect the surfaces
before the first coat of paint is applied.
4.2.3 Prior to applying each coat of paint, verify to the
COR or other person specified by the COR that the conditions
exist as prescribed in paragraph 3.1.5.
4.2.4 After each coat of paint is applied and prior to the
next coat, take DFT readings in accordance with reference 2.a.
The COR or other person specified by the COR shall be permitted
to witness the measurements. Provide magnetic gages, calibrated
immediately before taking the measurements in presence of the
COTR or other person specified by the C< 11' .
4.2.5 In the event the COR or other person specified by
the COR is unable to witness the required inspections and
measurements, the Contractor shall nonetheless conduct and
document the inspections and measurements to verify compliance
with the requirements of this specification.
5. NOTES.
5.1 The surfaces and extent of coating to be applied will be
specified in other procurement documents or specifications.
5.2 A paint system may be specified for use in any location or
for any purpose. However, the systems are normally used in the
following applications:
System Normal Use
STL-1 Appearance is unimportant.
STL-2 Exterior freeboard and superstructure
STL-3 Bilges
STL-4 Chain lockers and tanks, including potable
.-.„„jr tanks
STL-5 CHT/MSD tanks
STL-6 Interior bulkheads, overheads, insulation
STL-7 Hot surfaces exceeding 125 degrees Fahrenheit
STL-8 Surfaces subject to condensation
STL-9 Decks requiring non-skid
STL-10 Decks requiring non-skid
STL-11 Voids, bilges, and tanks (not approved for potable water tanks
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APPENDIX A
ACCEPTABLE INO
Product
Carbozinc 11 HFP
Galvosil 1570
Metalhide 100
Mobilzinc 7
Mobilzinc 13-F-12
Uni-Pac 13-C-10
Rust-Ban 191
Rust-Ban 188
Zinc-ite
Interzinc HF-2410/2411
Interzinc 2410/2411
Quram 3365 WZ
Zinc Prime 200
BPS Vitazine 294
Stancoat 711R
Farbozinc 7 6
Farbozinc 114
Durazinc 500
Pro-zinc 202
Briner Five-65
Phyllyzinc 1
SA-134 4 6/SA-13447
Rel-Zinc No. 63
(gray-green)
Zincguard No. 3
Zincguard No. 6
Zinc-Lock 351-NF and
Zinc-Lock 351-HF
Ganicin 347-934:EID
Ganicin 347--947
Napko 5-Z (high flash)
iiitieron zudd and
Dimetcote 9HF
Mo-Zinc No. 4
Sray 28-DH-51)
Mo-Zinc No. 5
(Green 28-DH-52)
ByCo Zinc-Gard 102-SP
IC Jnorganic Zinc
CaLiiacoat 304
lNIC ZINC SILICATES
Manufacturer
Carboline Company
Hemple's Marine
Pittsburg Plate Glass
Mobil Chemical
Mobil Chemical
Mobil Chemical
Exxon Chemical
Exxon Chemical
Plus-Chemical
International Paint
International Paint
Philadelphia Quartz
Grow Chemical
Patterson Sargent
Standard Paint & Varnish
Farboil
Farboil
Southern Imperial Coatings
Proline Paint
Briner Paint Manufacturing
Philadelphia Resins
Andrew Brown
leliance Universal
Sherwin-Williams/Seaguard
Sherwin-Williams/Seaguard
irter Paint
Dupont de Nemours
Dupont de Nemours
Napko
Ameron
Valspar Ind.
Valspar Ind.
Bywater Coatings
Inorganic Coatings
Devoe Marine Paint and
Coatings
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APPENDIX B
30-PERCENT MODIFIED SILICONE ALKYD PAINTS
Product
Gloss Silicone Alkyd(series)
SA-22 Silicone Alkyd
CMB000 Silicone Alkyd
Silalx 300
21-W-9 Silicone Alkyd
434U-1000 Silicone Alkyd
Series 5539
40-E Silicone Alkyd
HM-7 0
MIL-E-24 635
Manufacturer
Devoe Marine Coatings
Porter Coatings
International Paint
International Paint
Valspar
Hempel's Marine Paints
Glidden Coatings and Resins
Farboil
Carboline
Sherwin-Williams/Seaguard
END OF SPECIFICATION
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MOOING
AMC-997-1 MARCH 1988
U.S. Environmental Protection Agency (USE
Mid-Continent Ecology Division
STANDARD SPECIFICATION EPA-000-4
DRYDOCKING AND ROUTINE DRYDOCK WORK
1. SCOPE. This specification contains the general requirements
for drydocking and routine drydock work on EPA ships.
2. REFERENCES.
a. Docking Report, Form 2410
3. REQUIREMENTS.
3.1 Submittals. Prior to drydocking the ship, submit to the
COR the following:
3.1.1 Provide a certification signed by a qualified
independent firm attesting that the drydock or railway, and
associated controls and machinery, are in good sound condition
and have adequate capacity to safely drydock the ship. The
certification shall be based on a visual inspection of the
facility within the 12-month period immediately preceding the
scheduled drydocking, operating and maintenance records of the
facility, and recent demonstration of the facility's capacity
(e.g., record of the largest ship drydocked during the preceding
6 months). Submittal of a NAVSEA certification that the drydock
or railway meets the requirements of MIL-STD-1625 A/B(SH) may be
substituted for the independent firm certification.
3.1.2 Provide a letter certifying that the dockmaster in
charge of the docking and undocking evolutions is professionally
qualified, through training and experience, to conduct the
evolutions in a safe and reliable manner. Include a copy of the
dockmaster's resume attached to the letter.
3.1.3 Prepare and submit a drydocking and undocking
procedure which includes operating practices, special precautions
that are required by the characteristics of the dock or ship,
depth of water, and tide and current conditions which will exist.
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3.2 Preparations for Drydocking.
3.2.1 Arrange the blocks in the Contractor's drydock or
railway in accordance with the ship's docking plan. Blocks shall
be positioned to haul the ship in the position specified in the
detail specification item. In the event the detail specification
item does not specify a docking position, the COR shall specify
the docking position.
3.2.2 The minimum height of keel blocks shall be as
specified on the ship's docking plan or the detail
specifications. In event a conflict exists between the docking
plan and the detail specifications, the detail specifications
take precedence. If not specified on docking plan or in the
detail specifications, the minimum height shall be 36 inches.
All keel blocks shall have 2 inches minimum soft wood caps.
3.2.3 Insure that all sea chests, discharges, transducers,
domes, and other appurtenances are clear of all blocks. There
shall be no obstructions between the floor surface of the drydock
and the hull, hull openings, appendages, and fittings. Ample
horizontal and vertical clearance shall be provided for removal
and replacement of rudders, bow thrusters, fathometers, sea
scanners, and sonar gear on the ship, whether or not such
removals or replacement are known to be required.
3.2.4 Record the fore and aft draft mark readings of the
ship prior to drydocking and after undocking.
3.3 Drydocking.
3.3.1 After obtaining the consent of the COR, carefully
haulout the ship without strain or injury, in a drydock or marine
railway. If any tendency to strain or injure the ship is
observed, immediately refloat the ship and rearrange the blocks
or make other corrections required to relieve the condition.
Wash down the dock basin to remove silt, mud, and debris
immediately after the ship is drydocked.
3.3.2 Prior to the keel clearing the water, attach two
grounding cables from the ship's hull to ground to protect
against lightning or other static discharges. One of the cables
shall be connected near the bow and the other cable shall be
connected near the stern. Each cable shall be a minimum size of
5pn, nnn i ^ r
. . ¦ ship shall be drydocked within the first
25-percent or the time allowed for the contract performance
period.
3.3.4 Hold the ship out of the water for the period required
to perform all contract work which necessitates drydocking.
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3.4 Cleaning.
3.4.1 As soon as practical, but in all cases within 12 hours
after drydocking the ship, clean the entire underwater hull and
boottopping of all marine growth, dirt and loose paint using
stiff bristle brushes, scrapers, and high pressure fresh water.
Included shall be sea strainer plates, sea chests, bow thrusters,
rudders, propellers, shafts, struts, and other underwater hull
appendages.
3.4.2 Exercise extreme care to avoid scratching, gouging or
otherwise damaging any transducers, dome windows, shaft coverings
or other appendages.
3.4.3 Clean fiberglass surfaces using non-metallic scrapers
and bristle brushes. Clean transducers using non-metallic,
non-abrasive brushes. Do not use scrapers on transducers.
3.5 Miscellaneous Requirements.
3.5.1 All hull discharge openings and scupper drains shall
be fitted with discharge fittings and be fitted with spigots and
hoses to direct liquids away from the hull. Hull discharge
openings which will not be in service while the ship is in
drydock may be plugged in lieu of being fitted with the fittings,
spigots and hoses.
3.5.2 Within 24 hours after drydocking, remove all sea chest
covers, strainer plates, rope guards, and fairwaters. After
completion of all inspections and acceptance of inspection
condition reports by the COR, reinstall the items removed.
3.5.3 Provide adequate staging, or other safe means
acceptable to the COR, to accomplish all contract work and to
permit a thorough inspection (see below) of the underwater body.
q K . 4 Clean all anodes with a wire brush to remove all
corrosion products. Polish propellers and bow thrusters to
bright metal.
3.5.5 While the ship is in drydock, install temporary
closures over all hull openings during all hours outside the
normal work shifts. Blank flanges and closure plates shall have
sufficient strength to prevent water entry into the hull in the
event of drydock failure or flooding.
3.5.6 Provide to the COR a "marked-up" copy of the docking
plan showing all alterations and modifications made to the
underwater hull during the contract.
3.6 Docking Inspection. Within 48 hours after drydocking, a
joint inspection of the ship's underwater hull shall be conducted
by the Contractor, the COR, and the Commanding Officer/Master's
representative. Submit a Condition Report of the inspection
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findings, including a completed preliminary copy of reference
2.a. A blank copy of reference 2.a will be provided to the
Contractor by the COR. The inspection shall include the
following:
3.6.1 Condition of the hull, particularly inspecting for
evidence of structural damage and deterioration of plating,
welds, and fasteners.
3.6.2 Condition of anodes and paint system.
3.6.3 Condition of propellers, rudders, sea chests, shafts,
overboard discharge piping, bilge keels, transducers, and all
other underwater hull appendages. Inspect for evidence of leaks,
damage, and deterioration.
3.7 Void Inspections. Remove the void plugs in underwater hull
rub rails, rudders, struts, fairing plates, bilge keels, and
other inaccessible underwater voids. As the plugs are removed,
inspect for drainage of water from the voids. If water is
present, advise the COR prior to proceeding. After the source
of the water has been determined and all additional work
authorized by the Contracting Officer has been completed, fill
the voids with a rust preventive compound complying with
MIL-C-16173, Grade 5. Drain the rust preventive compound and
reinstall the plugs using an anti-seize compound on the threads.
3.8 Packing Renewal. Remove the packing glands and existing
packing from the rudders and tailshafts. Thoroughly clean the
glands. Cut and fit new rings of TFE-impregnated square flax
packing in the rudder and tailshaft glands. Packing shall not
contain graphite. Stagger the butts. The number of packing
rings shall be as shown on applicable drawings if available.
Otherwise, the number of packing rings shall be same as removed.
Reinstall glands. After the ship is undocked, readjust the
tailshaft glands such that a fine trickle of water provides
cooling.
3.9 Clearance Readings.
3.9.1 While the packing is removed, take a complete set of
rudder stock and pintle bearing clearance readings. Also check
and record the vertical movement of the rudders. Raise the
rudders approximately 1/8-inch to relieve weight from the thrust
plates. Disassemble the upper support bearing assembly for
inspection. Clearance readings of the rudders are to be taken at
both the lower hull penetration and the internal upper bearing
surfaces. Measure weardown of all packing gland sleeves. After
completion of inspections, reassemble all bearings.
3.9.2 Take clearance readings of each propulsion shaft
cutlass bearing at 90-degree intervals around the shafts'
circumferences. Clearances of strut bearings shall be taken at
both the forward and aft sides of the struts. While packing is
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removed, measure and record the weardown of the shafts and
sleeves at the packing gland.
3.10 Runout Readings. Take runout readings of the propeller
shafts in place while the packing is removed. If the propellers
are removed under another contract item, set up a dial indicator
to bear on the after end of the shafts. If the propellers are
not removed, set the dial indicator to bear on another convenient
machined surface as near the end of the shafts as practical.
Read and record the dial indicator deflections as the shafts are
rotated 360 degrees. Set up a dial indicator and measure the
shaft deflections at each strut and stern tube bearing while the
shafts are rotated 360 degrees.
3.11 Transducers. Clean, protect, and paint all transducers as
follows:
3.11.1 Clean the exposed surfaces oi each Lransducer while
the surfaces are still damp. Clean transducers with non-metallic
brushes. Do not use scrapers.
3.11.2 Degrease the faces of rubber-faced transducers with
mineral spirits and rinse with fresh water. Do not use
detergents on the rubber faces. Swab metallic-faced transducers
with a solution of one part nitric acid to five parts fresh
water, and follow with ricn soapy water wash and fresh water
rinse. Polish metallic-faced transducers with crocus cloth.
3.11.3 Coat all metallic-faced transducers with one coat of
anti-foulant same as prescribed for the remainder of the
underwater hull. This is to be accomplished by removing the
plywood protective covers immediately prior to applying the last
coat of paint to the underwater hull. If the underwater hull is
not being painted, apply one coat of anti-foulant same as exists
on underwater hull. All painting shall be in accordance with the
paint manufacturer's printed recommendations and instructions.
3._l_l.4 Coat all rubber-faced transducers with two coats, 2.0
dry mils each, of MIL-P-22298 Formula 133 and two coats, 2.0 dry
mils each, of MIL-P-22299 Formula 134 in accordance with the
paint manufacturer's printed recommendations and instructions.
3.11.5 EPA reserves the right to inspect and adjust
transducers.
3.11.6 Except when work is being performed on the
transducer, cover the transducer faces with a plywood protective
cover. do not apply props or forced pressure on the face of the
transducers.
3.12 Undocking.
3.12.1 After all work requiring drydocking has been
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completed, carefully undock the ship. Flood the drydock or lower
the railway until as many underwater openings as possible are
covered with water, but without lifting the ship off the blocks.
Provide adequate personnel and check for leaks. If leaks are
found, redock the ship and repair the leaks. If no leaks are
found or after repair of all leaks, continue with undocking the
ship.
3.12.2 Unless authorized by the Contracting Officer, the
ship shall not be undocked until all work which requires
drydocking has been completed, including all work included in the
initial contract award and all additional work authorized or
being negotiated. In the event the Contractor desires to undock
the ship and subsequently redock the ship for completion of work,
submit to the Contracting Officer a letter request which clearly
outlines the reasons for the request. If the Contracting Officer
decides to grant the request, the extent of Government's
liability for costs related to the undocking and redocking shall
be limited to the additional layday costs for which the
Government would be liable if the ship were not undocked and
redocked.
4. QUALITY ASSURANCE.
4.1 After the blocks have been set ana Before lowering the
drydock or railway for hauling the ship, a final inspection of
the blocking shall be conducted by the COR and the dockmaster.
Measurements shall be rechecked as necessary to satisfy the COR
that the block locations are in accordance with the docking plan
and other contract requirements have been met. Acceptance of the
blocking arrangement by the COR in no way relieves the
Contractor of the responsibility for safely drydocking the ship
without strain or damage.
END OF SPECIFICATION
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SUPERSEDING
AMC-631-3B
JUNE 1991
U.S. Environmental Protection Agency (USEPA)
Mid-Continent Ecology Divison
STANDARD SPECIFICATION EPA-000-5
UNDERWATER BODY ABLATIVE COATING SYSTEM
1. SCOPE. This specification contains the general requirements
for application of an ablative coating system on the underwater
body of NOAA steel ships and boats, using sandblasting or ultra-
high pressure water blasting procedures for surface preparation.
2. REFERENCES.
a. Steel Structures Painting Council Surface Preparation
Specification No. 10 (SSPC-SP 10-85), "Near White Blast Cleaning"
b. Steel Structures Painting Council Paint Application
Specification No. 2 (SSPC-PA-2), "Measurement of Dry Paint
Thickness with Magnetic Gages"
3. REQUIREMENTS.
3.1 General Requirements.
3.1.1 The ablative anti-foulant coating system shall be a
copper-based tributyltin-free system. Two systems currently
authorized for use by this specification are the International
FP Epoxy/BRA Antifoulant (International Paint Co.) and the Devran
234QC Epoxy/ABC-AF #3 Antifoulant (Devoe Marine Coatings).
3.1.2 The underwater body is defined as the entire
underwater hull plating and all appendages up to the upper
boottopping limit. Included are all rudders, struts, skegs,
bilge keels, sea chest strainer plates, sea chests, domes,
propulsion shafting, fairwaters, rope guards, and the bow
thruster tunnel.
. . :opping lines shall be carefully cut in. The
boottopping shall be same as existing unless otherwise specified.
3.1.4 All paint materials shall be applied using spray
equipment, except sea chest strainer plates shall be coated by
dipping. After the last coat of anti-fouling paint has been
applied, the underwater body draft marks shall be repainted, with
brushes, using a high grade white gloss marine paint.
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3.1.5 All coating thicknesses are stated in dry film
thickness (DFT). All dry film thickness determinations shall be
performed in accordance with reference 2.b.
3.1.6 Coatings shall be applied only when the following
conditions are maintained:
a. Apply paint only to dry surfaces and when there is
no chance of precipitation until after the paint has cured. The
temperature of the surface to be painted shall be at least 5
degrees Fahrenheit above the dew point at the jobsite. The
dewpoint can be presumed to be satisfactory if a thin, clearly
defined film of water applied to the cleaned surface with a damp
cloth evaporates within 15 minutes. Otherwise, the dew point
shall be measured prior to painting by taking the dry-bulb
temperature of the surface and the wet-bulb temperature at the
j obsite.
b. The air temperature and surface temperature must
both be a minimum of 45 degrees Fahrenheit at all times, unless a
lower temperature is specifically authorized by the paint
manufacturer's printed instructions. In no instance shall the
air or surface temperature be less than 35 degrees Fahrenheit.
c. Painting is permitted onlv when the humidity is
less than 95 percent.
d. In the event the Contractor desires or must proceed
with painting when the existing weather conditions do not meet
the above specified conditions, the Contractor shall erect a
cover over the surfaces to be painted and shall heat the surfaces
and the surrounding air to establish the required conditions.
The conditions shall be maintained until the paint has fully
cured
3.1.7 Bilge blocks shall be shifted to allow all their
contact areas no be prepared and painted. The Dockmaster shall
be consulted to determine the sequence of shifting blocks. Keel
blocks need not be shifted unless otherwise specified.
3.1.8 Comply with the manufacturers' printed
recommendations and instructions for all aspects of handling,
mixing, and application of the paint materials.
3.1.9 All paint shall be delivered to the jobsite in
original, unopened containers with labels intact. All containers
shall remain unopened until required for use. Each container of
paint shall be clearly marked or labelled to show paint
identification, date of manufacture, batch number, analysis of
contents, identification of all toxic substances, and special
instructions.
3.1.10 Each coat of paint shall be in a proper state of
cure or dryness before the application of the succeeding coat.
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Paint shall be considered dry for recoating when an additional
coat can be applied without the development of any detrimental
film irregularities, such as lifting, wrinkling, or loss of
adhesion of the undercoat. The time interval between coating
applications shall be in compliance with the manufacturer's
printed instructions. The final coat of anti-fouling paint shall
be allowed to cure a minimum of 24 hours prior to undocking the
ship.
3.1.11 Comply with and enforce all safety and environmental
protection regulations relative to removal, disposal, mixing, and
application of paints and other material, .
3.2 Surface Preparation.
3.2.1 Whenever the detail specifications requires the
underwater body be coated with a "complete system", the entire
underwater body is to be prepared as follows:
a. Prior to any sandblasting, all sea chests strainer
plates shall be removed and all hull openings, transducers,
anodes, waster pieces, bearings, stern tube openings, bow
thrusters, fiberglass covers (over shafts and domes) and
propellers shall be plugged, covered, and otherwise protected
from damage or contamination during surface preparation and
coating application.
b. Sandblast all steel surfaces to near white blasted
surfaces in accordance with reference 2.a.
c. After sandblasting, surfaces shall be brushed with
clean brushes, blown off with compressed air, or cleaned by
vacuum to remove all traces of blast products and dust.
3.2.2 Whenever the detail specifications require the
existing coating system on the underwater body to be coated with
a "maintenance system", the underwater body shall be prepared as
follows:
a. Prepare the entire underwater body (except
fiberglass surfaces and transducers) with a high pressure wash,
using a controlled close high pressure water wash spray at a
pressure of not less than 3000 psi, to clean the surface to a
condition acceptable to the paint manufacturer's on-site
representative. If salt water is used for an initial high
pressure water wash, the water wash shall be followed with a
final high pressure fresh water wash.
b. After the water washed surfaces have been allowed
to sit for 24 hours, the COR will designate areas to be
sandblasted. The detail specifications will state the amount (in
square feet) that will be required to be sandblasted. Prepare
designated areas by sandblasting using the same procedure
required above for the "complete system".
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3.2.3 Regardless of whether a "complete system" or a
"maintenance system" is required, all fiberglass surfaces shall
be prepared as follows:
a. Use wooden or plastic scrapers, mechanically
prepare to a bare clean surface, exercising care not to gouge,
scratch, or otherwise damage the fiberglass.
b. Using a hand or finishing sander with fine grit
paper, remove all remaining marine growth, loose paint, and dirt.
Wipe the surfaces with a damp soft cloth to remove all dust and
residue.
3.2.4 Ultra High-Pressure Water Blasting (UHPWB) may be
used in lieu of sandblasting when indicated in the detailed
specifications. UHPWB can only be used on steel surfaces that
have been sandblasted previously (prior to installation or during
previous drydockings) with sufficient profile to ensure coating
adhesion. The requirements for UHPWB include:
a. Degree: HB 2 ^ Light
b. Water Pressure: Between 36,000 and 40,000 psi
3.3 Coating Systems. After surface preparation, apply either a
complete system or a maintenance system (as specified in the
detail specifications) as follows.
3.3.1. Complete System. When a "complete system" is
required by the detail specifications, apply one of the two
following 5-coat coating systems after completing surface
preparation. The first coat is to be applied as soon as
practical after surface preparation and before any rusting
occurs. In no case shall the surfaces be allowed to remain
overnight without coating.
a. International System.
i. Two coats, 5.0-6.0 mils DFT each,
International FP series epoxy. First coat shall be FPD052 (off-
white) and second color shall be FPK705 (gray).
Three coats, 4.0-5.0 mils DFT each,
International BRA500 series ablative antifoulant. The first and
third coats shall be BRA570 red and the second coat shall be
BRA572 black, except in the boottopping all three coats shall be
BRA572 black.
b. Devoe System.
1. Two coats, 5.0-6.0 mils DFT each, Devran 234
epoxy. The first coat may be any color, but second coat shall be
gray.
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2. Three coats, 4.0-5.0 mils DFT each, Devoe ABC
3 ablative antifoulant. The first and third coats shall be red
and the second coat shall be black, except in the boottopping all
three coats shall be black.
3.3.2 Maintenance System. Whenever a "maintenance system"
is required by the detail specifications, apply the following
coating system after completion of surface preparation. The
coating materials shall be provided by the same manufacturer as
the existing system.
a. To all sandblasted areas, apply a complete 5-coat
coating system same as specified above for the "complete system".
The first coat is to be applied as soon as practical after
surface preparation and before any rusting occurs. In no case
shall the surfaces be allowed to remain overnight without
coating.
b. To all prepared surfaces mat are not sandblasted,
apply two new coats, 4.0-5.0 DFT each, of the same ablative
antifoulant as existing (last three coats of one of the complete
systems specified above). The first new coat shall be black and
the second new coat shall be red, except in the boottopping both
new coats shall be black.
4. QUALITY ASSURANCE.
4.1 Certification and Records.
4.1.1 Provide the on-site services of a manufacturer's
representative for the coating system being applied. The
representative shall be on-site during all mixing and application
of paint, and shall conduct or witness all inspections. All
surface preparation and other aspects of the coating system
application shall be acceptable to the paint manufacturer's
representative.
4.1.2. Prior to commencing the surface preparation:
a. Provide the COR with a detail "Paint Plan" which
clearly outlines the complete painting timetable and procedures,
including methods for conducting and documenting inspections.
The "Paint Plan" shall be approved by the manufacturer's
representative before submitting it to the COR. Attach copies
of all applicable manufacturers' printed recommendations,
instructions and product data sheets to the "Paint Plan.
b. The Contractor's paint foreman and the paint
manufacturer's representative shall meet with the COR to discuss
and review the "Paint Plan".
4.1.3 Provide the COR with the following information:
a. Number of gallons of each type paint used.
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b. Certification by the Contractor's paint foreman and
the paint manufacturer's representative that the conditions
specified in 3.1.6 were maintained during application and curing
of the paint. If measured, the wet-bulb temperature at the
jobsite and the dry-bulb temperature of the surface immediately
before applying each coat of paint.
c. Date and time of starting and completing each coat
of paint.
d. Complete set of all DFT measurements taken.
e. A copy of paint manufacturer's representative
service report which outlines all inspections, observations, and
recommendations provided by the representative.
4.2 Inspections.
4.2.1 Prior to any sandblasting or UHPl/vts, conduct an
inspection with the COR of all protective coverings to insure
that the protection is adequate.
4.2.2 After completion of surface preparation, the paint
manufacturer's representative shall inspect the surfaces before
the first coat of paint is applied. The COR shall be notified
of the inspection and allowed an opportunity to witness the
inspection.
4.2.3 Prior to applying each coat of paint, verify to the
COTR and the paint manufacturer's representative that the
conditions exist as prescribed in paragraph 3.1.6.
4.2.4 After each coat of paint is applied and prior to the
next coat, take DFT readings in accordance with reference 2.b.
The paint manufacturer's representative shall witness the
measurements. The COR shall be notified of the inspection and
allowed an opportunity to witness the inspections. Provide
magnetic gages, calibrated immediately before taking the
measurements in presence of the paint manufacturer's
representative.
END OF SPECIFICATION
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SUPERSEDING
AMC-505-1B
SEPTEMBER 1990
U.S. Environmental Protection Agecny (USEPA)
Mid-Continent Ecology Division
STANDARD SPECIFICATION EPA-000-6
VALVE OVERHAUL AND TEST
1. SCOPE. This specification contains the general requirements
for overhaul and test of valves on and for NOAA ships and boats.
2. REFERENCES.
None
3. REQUIREMENTS.
3.1 Standard Overhaul. Overhaul all specified valves as
follows:
3.1.1 Except for valves which have welded ends preventing
removal without cutting the welds, or unless otherwise specified
in the detail specification or other applicable procurement
document, remove all specified valves from the ship or boat to a
suitable machine shop for overhaul and tests. Specified valves
which are not removed from the ship or boat shall be overhauled
in place. See paragraph 3.2 for special requirements for sea
valve removals.
3.1.2 Tag each valve prior to removing from the ship or
boat.
3.1.3 Completely disassemble each valve. Matchmark valve
parts. Thoroughly clean bonnets, stems, discs, gates, globes,
seats, bodies, and other metal parts to bright metal.
3.1.4 Deleted.
3.1.5 Clean and chase all valve stem threads. Check stems
for straightness. Straighten stems to within 0.002 inch total
indicator runout (TIR). Polish stems to a 32 Root-Mean-Square
(RMS) finish in way of packing surface and remove all raised
edges
3.1.6 Visually inspect all parts, including all fasteners,
for deterioration and other defects. Clean, dress, and true
gasket mating surfaces.
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3.1.7 Check the disc-to-seat, globe-to-seat, and plug-to-
bore contact fits using the bluing transfer method. Machine,
grind, lap, spot-in, and recheck contact fits as necessary to
obtain the following contacts:
a. Globe, globe angle, and globe stop-check valves
shall have a 360-degree continuous globe-to-seat contact with a
bluing transfer line not exceeding 1/16-inch width.
b. Gate valves shall have a 360-degree continuous
gate-to-seat contact with a bluing transfer line which does not
exceed 3/16-inch width. The transfer line shall appear within
the lower 50-percent of the gate seating surface at the top and
bottom of the gate.
c. Plug valves shall have a minimum 80-percent plug-
to-bore surface contact, evenly distributed over 100-percent of
the area.
d. Swing-check valves shall have a 360-degree
continuous disc-to-seat contact.
3.1.8 If unable to obtain the above specified contact fits
by machining, grinding, and lapping, renew the globes, plugs,
discs, gates, and renewable seats. Contractor may, at their
option and at no additional cost to the Government, renew globes,
plugs, discs, gates, and renewable seats after initial
inspections and before machining, grinding, or lapping the
existing parts to obtain the required contact fits.
3.1.9 (Modified and relocated to section 3.2)
3.1.10 Reassemble each valve. Insure that discs, gates,
and plugs are in the half-open position during reassembly to
avoid damaging seats or bending stems. Renew all gaskets,
fasteners, rubber seals, and non-metallic seats. In butterfly
valves, renew boots, o-rings, o-ring fasteners, and teflon
bushings. Renew valve stem packing in feed water, condensate,
and steam valves with packing conforming to MIL-P-24503 and DOD-
P-24583. Renew valve stem packing in all other valves with
packing conforming to MIL-P-24396, Type B.
3.1.11 Prior to disassembling and overhauling a valve, the
Contractor may, at their option and at no additional cost to the
Government, renew the valve with an identical valve. If this
option is exercised, the new valve must be tested and meet the
same acceptance criteria as prescribed herein for overhauled
valves. If a valve is determined after disassembly to be
nonrepairable, the Government will negotiate an equitable cost
adjustment, limited to the difference between the cost of the new
valve and the costs which would have been incurred had the valve
been overhauled. For valves of 3-inch IPS size and below, the
cost adjustment will be limited to the costs incurred associated
with disassembling the valves.
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3.2 Additional Sea Valve Requirements.
3.2.1 Inspect all studs, bolts, and nuts in line and bonnet
flanges of non-ferrous sea valves to determine the material. If
the fasteners are not nickel-copper (Monel), submit a Condition
Report giving the actual material, condition, and
recommendations.
3.2.2 Coat the interior of each steel valve, excluding
seating and polished surfaces, with the same epoxy primer used on
the underwater body.
3.2.3 Remove all waster pieces and spool pieces installed
between the sea valves and the ship's hull. Thoroughly clean the
waster and spool pieces, and inspect for deterioration or other
defective conditions. Inspect all fasteners and submit a
Condition Report same as specified above for sea valves.
3.2.4 Whenever a transducer sea chest valve is required to
be removed for overhaul, extreme care must be taken to prevent
damaging the transducer assembly. Remove and reinstall the
transducer assembly in accordance with the transducer
manufacturer's technical manual, a copy of which will be provided
by the COTR within 48 hours after requested.
3.3 Tests. After reassembling or renewing, conduct hydrostatic
tests of each valve as follows:
3.3.1 All tests shall be performed using clean water as the
test medium. Unless otherwise specified, the test pressure shall
be 150-percent of the maximum operating pressure of the system
from which the valve was removed, but not less than 50 pounds-
per-square-inch-gage (psig).
3.3.2 With the valve in the open position, test each valve
body for 10 minutes. No leakage is allowed.
3.3.3 Seat each plug and butterfly valve with hand force.
Seat all other valves using the torque values listed in the
following table as the maximum allowable seating force applied to
the handwheel.
Total Tangential Force
Handwheel Diameter (pounds) on Rim of Handwheel
2 inches and below
90
98
106
112
inches
inches
inches
id inches and greater
118 plus 3 pounds for
each inch above 6, not
to exceed 150 pounds.
3.3.4 Test each globe, angle globe, and globe stop-check
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valve by applying test pressure in the direction tending to open
the valve. Test each butterfly, gate, and plug valve by applying
test pressure alternately on both sides of the disc, gate, or
plug. Hold test pressure for a minimum of 3 minutes if there is
no evidence of leakage. If there is evidence of leakage, hold
the test pressure and measure the leakage rate.
3.3.5 Test each globe stop-check valve and swing-check
valve by applying test pressure in direction tending to close the
valve (back pressure) for a minimum of 5 minutes. If leakage
occurs, hold the test pressure and measure the leakage rate.
Globe stop-check valves shall be tested with stems in the open
position. The test back pressure for valves having a pressure
rating of 150 psig and below shall be 50 psig, and for valves
having a pressure rating over 150 psig shall be 100 psig.
3.3.6 The seat leakage shall not exceed the following:
a. Check valve back pressure tests -- For valves up to
and including 2 inches, the leakage rate shall not exceed 25
cc/hour/inch diameter. For valves 2-1/2 to 10 inches, the
leakage rate shall not exceed 50 cc/hour/inch diameter. For
valves over 10 inches, the leakage rate shall not exceed 100
cc/hour/inch diameter.
b. Soft-seated valves -- No leakage shall be
permitted.
c. Metal-to-metal seated valves -- For valves less
than 1 inch, the leakage rate shall not exceed 10 cc/hour. For
larger valves, the leakage rate shall not exceed 10 cc/hour/inch
of nominal pipe size.
3.3.7 Any valve which fails a seat leakage test shall be
renewed or overhauled and retested until an acceptable test is
performed.
3.4 Reinstallation. After tests have been accepted by the COR,
reinstall each valve, using new flange gaskets.
4. QUALITY ASSURANCE.
4.1 Prior to requesting the COR to witness the final bluing
contact inspection or the final acceptance hydrostatic tests of a
valve, the Contractor shall perform preliminary inspections and
tests which meet the acceptance criteria stated above.
4.2 After acceptable preliminary inspections and tests have been
conducted, the Contractor shall notify the COR and conduct final
acceptance bluing contact inspection and final acceptance
hydrostatic tests of each valve in the COR's presence.
END OF SPECIFICATION
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SUPERSEDING
AMC-077-1A
August 1995
U.S. Environmental Protection Agency (USE
Mid-Continent Ecology Deivision
STANDARD SPECIFICATION EPA-000-7
ASBESTOS-CONTAINING MATERIALS
1. SCOPE. This specification contains the general requirements
for monitoring, handling, removing, disposing, and all other
activities related to asbestos-containing materials (ACM) by a
Contractor on or for USEPA ships and boats.
2. REFERENCES.
(a) 29 CFR 1915.1001
(b) (deleted)
(c) 40 CFR 61, Subpart M, sections 61.140 through 61.157
(d) Deleted
(e) Deleted
3. REQUIREMENTS.
3 .1 Genera.n .
3.1.1 Except as otherwise specified, the contractor shall
provide all labor, material, equipment, services, tools,
facilities, supervision, and technical expertise needed to
accomplish the work required by this specification.
3.1.2 The contractor shall be responsible for compliance
with all applicable federal, state, and local regulations,
ordinances, and standards. In the event a conflict should exist
between this specification and any applicable regulation,
ordinance, or standard, the requirement(s) of the regulation,
ordinance, or standard shall take precedence. In those instances
where this specification may be more stringent or explicit,
comply with this specification.
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3.1.3 Whenever federal, state, or local regulations,
ordinances, or standards require compliance by the "owner" or
"operator", the contractor shall be fully responsible and liable
for the compliance.
3.1.4 Definition of terms used in these specifications
shall be the same as those used in references (a) and (c).
3.1.5 The contractor shall provide a full-time ACM Project
Manager who has overall responsibility for compliance with this
specification and all applicable federal, state and local
regulations relating to ACM. The Project Manager shall be
experienced in administration and supervision of asbestos
abatement projects including ACM identification, work practices,
protective measures, and disposal procedures. The Project
Manager shall be a Qualified Person as defined in and meeting the
requirements of reference (a). This person must have a minimum
of two years on-the-job training in asbestos abatement
procedures.
3.1.6 For purposes of this specification, Appendices B and
F of reference (a) shall be considered "mandatory" and all work
shall comply with the recommendations contained therein.
3.1.7 Deleted
3.1.8 The Contacting Officer's Representative (COR)
is the government official responsible for inspecting the
work, monitoring progress, and accepting the work. Normally, the
COR will be designated in the ordering procurement document. If
not designated in the ordering procurement document, the COR
shall be the person specified by procurement document authorizing
official (Contracting Officer or other procurement agent).
3.2 Work Site Inspections. Within 24 hours after commencement
of the contract performance period, conduct an inspection of each
work site that will involve a demolition or renovation operation
as defined and required by reference (c). The inspection shall
be conducted by the ACM Project Manager. Within 24 hours after
the inspection(s), the Project Manager shall submit a report to
the COR for each work site. The report shall be submitted using
the form shown in Appendix A. A contractor-generated form may be
substituted for Appendix A if it provides all the information
shown of Appendix A.
3.3 Asbestos Handling Plan.
3.3.1 At least three working days before the scheduled
start of any work with ACM, the Contractor's ACM Project Manager
shall prepare and submit to the COR two copies of an "Asbestos
Abatement Plan." Earlier submittal should be made when practical
to allow time for corrections and resubmital, if necessary.
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3.3.2 As a minimum, the "Asbestos Abatement Plan" shall
contain the following:
a. Detailed procedures for removal, handling, and
disposing of the asbestos-containing materials. Include
sufficient details to demonstrate compliance with refe^^^es (a)
and (c) and this specification.
b. Physical description of the work area(s), including
locations and construction details of containment and
decontamination facilities.
c. Description of the approximate amount of each type
(Category I nonfriable, Category II nonfriable, and Friable) of
ACM likely to be disturbed during the work.
d. Statement regarding EPA-notification requirements
applicability. If notification is required, include a copy of
the completed notification form submitted to EPA.
e. Names and records of training provided to workers
involved with the ACM work, including persons designated as the
"Project Manager" and "Qualified Person."
f. An air monitoring plan, including description of
air sampling equipment, techniques, and frequency.
g. List of equipment and clothing to be worn or used
by workers.
h. Schedule for turning off and sealing existing
ventilation systems and a description of the local exhaust
ventilation system to be used.
"¦ . Details of the employee exposure monitoring
methods, policies, and procedures.
j. If the work is to be accomplished in a State that
requires that asbestos workers or contractor, or both, be
licensed, include copies of the licenses in the plan.
k. Description of work practices to be observed by
workers, including methods to be used to remove ACM and
description of wetting agents to be used.
_L. jjescription of the method to be used to seal and
transport ACM waste materials.
m. Location and name of the waste disposal site,
including the EPA license number.
n. Description of cleanup procedures to be used
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following asbestos removal before opening the work site to
unrestricted access.
o. Procedures and circumstances for reporting events
of unusual and significant nature.
p. Contingency plan for emergencies, including fire,
accident, power failure, negative air system failure, supplied
air system failure, and any other event that may require
modification or abridgment of decontamination or work area
isolation procedures.
3.3.3 Within three working days after the plan's receipt,
the COR will return a copy of the plan to the Contractor, marked
with one of the following actions:
a. "Accepted" indicates that the plan is returned for
unrestricted use as submitted to the COR without changes. Work
covered by the plan may proceed without further direction.
b. "Accepted as Noted" indicates that the plan is
returned for changes or corrections as noted on the submittal or
provided separately. Acceptance is conditional upon the changes
being made, but resubmittal of the plan is not required. Work
covered by the plan may proceed after the changes have been made.
c. "Not Accepted" indicates that the plan is returned
for changes noted on the submittal or provided separately. The
plan must be revised and resubmitted. Within three workdays
after receipt of the revised plan, the COR will return a copy to
the Contractor, marked with one of the actions indicated herein.
3.3.4 No ACM-related work shall start until the "Asbestos
Abatement Plan" has been accepted by the COR. Acceptance by the
COR does not relieve the Contractor of the responsibility for
full compliance with all local, state, and federal regulations,
laws, and ordinances.
3.4 Government-Furnished Services. If the work is being
performed on a ship at a government facility and unless otherwise
specified, USEPA will provide the following temporary services to
assist the Contractor during ACM-related activities.
3.4.1 Electricity. Adequate electrical service will be
provided either on the ship or on the dock for operating the
Contractor's tools and equipment. The Contractor shall be
responsible for making all electrical connections and for
providing all cables, plugs, adapters, and other materials for
making the connections.
3.4.2 Water. Water service will be provided for use in
accomplishing the work. Service will be limited to that which
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can be provided by the government's installed equipment and does
not include providing of any hoses or fittings.
3.5 Air Monitoring.
3.5.1 The Contractor shall collect air samples in
sufficient numbers and locations as needed to satisfy all
federal, state, and local regulations. Notwithstanding the
regulatory requirements, the Contractor shall collect as a
minimum the following air samples:
a. Before starting work, establish a base line of air
quality by taking two air samples inside each work area and one
sample from each area adjacent to a work area.
b. After start of work, take two samples daily from
inside each work area and two samples daily from each area
adjacent to each work area until cleanup of the work area has
been completed and the work area has been cleared for
unrestricted access by satisfying the release criteria specified
below.
c. After work area(s) has been cleaned and before
removal of isolation barriers, take five air samples of each work
area and five air samples outside the work area in a compartment
adjacent to a work area. Use aggressive sampling methods
specified below for collecting these samples. If additional
cleaning is necessary to satisfy the release criteria specified
below, the required air samples shall be repeated until the
release criteria have been satisfied.
3.5.2 All samples shall be analyzed promptly by a testing
laboratory accredited by the American Industrial Hygiene
Association. A verbal analysis report of each sample shall be
made available to the COR within 24 hours after the sample is
collected. Document each verbal report with a written report
within three working days after the sample is collected.
3.5.3 USEPA reserves the right, at its option, to take
additional air samples as desired to monitor the air quality in
and adjacent to each work area. All costs associated with
collection and analysis of these additional air samples will be
the responsibility of USEPA.
3.6 Work Area Cleaning and Clearance Procedures.
3.6.1 After all ACM has been removed from the work area,
thoroughly clean all surfaces. Clean surfaces from which ACM was
removed by wire brushing, HEPA vacuuming, and wiping them with
amended water. All surfaces in the enclosed work area must be
free of visible dust before final air samples are collected.
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3.6.2 Air samples collected after cleaning to satisfy the
release criteria shall be collected using the following
aggressive sampling methods:
a. Before starting the sampling pumps, direct the
exhaust from forced air equipment (such as a one horsepower leaf
blower) against all bulkheads, overheads, decks, ledges, and
other surfaces in the work area.
b. Place a 20-inch fan in the center of the work area.
Operate the fan on slow speed and point it toward the overhead.
c. Collect the air samples. Then turn off the fan.
3.6.3 The work area enclosure shall not be dismantled and
the work area shall not be opened to unrestricted access until
the air samples analysis' show that the release criteria have
been satisfied. The release criteria have been satisfied when
both of the following occur:
a. the average fiber concentration of samples
collected in the work area is not statistically larger than the
average of the samples collected outside the work area.
b. the final air samples collected inside the work
area show that asbestos fiber concentration is not greater than
0.01 f/cc.
3.7 Waste Shipment Records. For all asbestos-containing waste
material generated while working under the requirements of this
specification, the Contractor's ACM Project Manager shall
initiate a waste shipment record in accordance with reference
(c). Provide a copy of the waste shipment record to the COR
within 24 hours after shipping the ACM waste. Within 45 days
after the ACM waste was accepted by the transporter, provide to
the COR a copy of the waste shipment record that has been signed
by the owner or operator of the disposal site. If the signed
waste shipment record is not received by the COR, USEPA will
notify EPA of the deficiency. The COR's final acceptance of
work will not provided until the signed waste shipment record has
been received.
3.8 Replacement Materials. Unless otherwise specified, ACM
which is removed shall not be reinstalled. Instead, replace the
ACM with a suitable nonasbestos material as follows:
3.8.1 Overhead Panels. Replace ACM panels with vinyl-clad
aluminum panels having a color and texture that closely match the
existing ACM panels. The aluminum panels shall be a minimum of
.050 inches thick and shall be mounted to the overhead gridwork
with cadmium-plated self-tapping screws at 6-inch intervals along
the panel edges. The aluminum panels shall be insulated from
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steel gridwork using 1/8-inch thick by 1-inch wide Chromelock
insulating tape. Cover seams and edges of the new panels with
matching trim pieces. When completed, the new panels and trim
pieces shall blend with existing panels and trim to the extent
practical.
3.8.2 Bulkhead Panels. Replace ACM bulkhead panels with
new panels that match the existing panels as closely as
practical. The replacement panels shall be same thickness and
size, and shall be installed using the same techniques and
configuration as the existing. The color and patterns shall
match existing as closely as practical.
3.8.3 Insulation. Replace ACM insulation with new
insulation in accordance with references (d) or (e), as
applicable.
3.8.4 Other Materials. All other ACM materials shall be
replaced with new materials that, to the extent practical, match
the existing materials in composition, strength, design, type,
size, function, service and appearance.
3.8.5 COR Acceptance. Before ordering or installing
replacement materials, submit to the COR a sample of the
proposed replacement materials. Meet with the COR and discuss
the installation details to insure that the materials and
installation will be acceptable to the COR.
3.9 Check Lists .
3.9.1 Before and during each ACM removal or handling
operation, the ACM Project Manager shall complete the "Checklist
for Asbestos Work" provided as Appendix B.
.Q. 2 At the completion of each ACM removal or handling
operation, the ACM Project Manager shall complete the "Report of
Asbestos Work" provided as Appendix C.
3.9.3 Blank copies of the forms will be provided, upon
request, by the COR.
3.9.4 Submit two copies of each check list to the COR
within 24 hours after their completion.
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APPENDIX A
DEMOLITION OR RENOVATION OPERATION WC
PRE-WORK INSPECTION REPORT
)RK S"^771
SHIP:
DATE :
COMPARTMENT/AREA:
TYPE OF OPERATION SCHEDULED:
RECORD OF ACM FOUND
SUSPECT MATERIAL
DESCRIPTION
QUANTITY
FRIABLE/
NONFRIABLE
CAT
I or II
CONDITION
REMARKS:
INSPECTOR:
1
TITLE:
EMPLOYER:
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APPENDIX B
CHECK LIST FOR ASBESTOS WORK
ON USEPA SHIPS
SHIP:
DATE(S'
COMPARTMENT/AREA:
RESPOND "YES", "NO", OR "N/A" TO EACH OF THE FOLLOWING:
Has the "Asbestos Handling Plan" for this work been accepted by the COR?
Have air samples been collected prior to beginning ACM removals to establish a
base line?
Has the ship's ventilation system to the work area been turned off and
ventilation ducts sealed?
Has an isolation enclosure been constructed in accordance with Appendix F of
29 CFR 1915.1001?
Is the negative pressure and filter system installed and operating properly?
Have the following hygiene facilities been provided in accordance with 2 9 CFR
1915.1001: clean room? shower? eguipment room?
Have warning signs been posted?
Are adeguate ACM waste disposal containers on hand at the work area?
Have all workers been provided with and are they using proper NIOSH-approved
respirators and disposable protective clothing?
Is ACM being adequately wetted before removal?
Is ACM waste material being bagged/sealed promptly after removal?
~ "" ACM waste containers being properly labeled?
Are aai±y air samples Deing collected as required by the contract?
Has the work area been properly cleaned and air samples collected using
aggressive sampling methods? Has the release criteria been satisfied before
dismantling the isolation barriers?
Has all ACM waste been shipped to an approved ACM waste disposal facility and
a copy of all waste shipment records provided to the COR?
COMMENTS : (Explain all "NO" and "N/A" responses)
ACM PROJECT MANAGER SIGNATURE:
COMPANY NAME & ADDRESS
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APPENDIX C
REPORT OF ASBESTOS WORK
SHIP:
DATE(S'
LOCATION OF SHIP
COMPARTMENT/AREA
WORK DESCRIPTION
CERTIFICATION OF ASBESTOS CLEANUP
I have inspected the site in which the above asbestos work was
conducted and certify that the work site has been cleaned of all
visible asbestos debris.
All raw asbestos ends have been sealed to prevent airborne
contamination.
Air samples have been collected in accordance with Standard
Specification EPA-000-7. Laboratory analysis of the samples have
confirmed that the release criteria specified by EPA-000-7 has been
attained and the compartment/area is safe for unrestricted access.
I have directed the removal of asbestos hazard signs and have
requested that the ship's general ventilation be restored.
CERTIFICATION OF ASBESTOS REMOVED
The amount of asbestos removed from the ship was properly bagged,
sealed, and labeled. The asbestos was taken to the following licensed
disposal facility.
Facility:
License No,
Amount
lbs
oz
SIGNATI
DF
OJECT MANAGER:
DATE :
NAME AND
IESS OF CONTRACTOR:
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U.S. Environmental Protection Agency (USEPA)
Mid-Continent Ecology Division
STANDARD SPECIFICATION EPA-000-8
GENERAL REQUIREMENTS FOR ELECTRICAL/ELECTRONIC ITEMS
1. SCOPE. This specification provides general requirements for
work performed on electrical and electronic systems.
2. REFERENCES.
2.1 IEEE STD 45-1988, Recommended Practice for Electric
Installations on Shipboard (series)
2.2 U. S. Coast Guard 46 CFR 110 through 113, "Subchapter J -
Electrical Engineering"
3. REQUIREMENTS.
3.1 The contractor shall accomplish all work in these
specifications in accordance with the requirements of References
2.1 and 2.2, and using the best marine and shipbuilding
practices.
3.2 The quality of all materials provided by the contractor
shall be in accordance with References 2.1 and 2.2, suitable for
marine service, and have the same shape, color, and finish as the
existing or damaged materials when they were new.
3.3 All new cabling shall be low smoke and sized for the cable's
intended use.
3.4 All machinery, piping, cabling, ducts, insulation, paint
work, deck tile, or any other article removed, disturbed, or
damaged in the process of accomplishing the work required by
these specifications shall be replaced, renewed, or repaired.
All paneling removed shall be replaced, including any required
alterations. Paneling damaged by the contractor shall be renewed
equal to the original when new. All flanges and joints broken or
loosened shall be properly remade using new gaskets of the proper
size and material.
3.5 Aii sctronic racks installed shall be securely fastened to
overhead and deck structural or steel members to prevent
movement.
3.6 Any disturbed painted or varnished surfaces shall be
cleaned, painted, and/or varnished with original type and color
of paint or varnish.
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3.7 Any extension of electrical cabling shall be through a
junction box. Any removal of electrical cabling shall be to the
nearest junction box.
3.8 All electrical junction boxes, receptacles, hangers, and
miscellaneous electrical fittings shall be in accordance with
References 2.1 and 2.2.
3.9 All electrical cabling installed by the contractor shall be
run behind paneling in existing cableways and shall be securely
banded to the hangers. If existing cableways are not available,
new cableways shall be established.
3.10 All electrical cabling installed by the contractor shall be
identified at each end with embossed metal tags. Where cables
are marked within a junction or terminal box, nonconductive
labels shall be used. The contractor shall number cabling with a
marking system similar to that used on the ship.
3.11 All manufacturer's or supplier's standard warranties on
equipment installed on the ship shall be assigned in writing by
the contractor to the Government.
3.12 Three copies all manufacturer's technical manuals, prints,
and drawings shall be delivered to the COR. Spare parts and
surplus installation materials shall be delivered to the COR.
4. QUALITY ASSURANCE.
4.1 All items disturbed and all devices used, repaired, altered,
furnished, or installed by the contractor shall be demonstrated
to be fully operational upon completion of work.
ND OF SPECIFICATION
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U. S. Environmental Protection Agency (USEPA)
MID-Continent Ecology Division
STANDARD SPECIFICATION EPA-240-1
PROPULSION SHAFTS AND PROPELLE
1. SCOPE. This specification contains the general requirements for
inspection, repairs, and other work on propulsion shafts and propellers
of EPA ships.
2 . REFERENCES
None
3. REQUIREMENTS
3.1 General
3.1.1 The contractor shall provide all labor, material, services,
tools, supervision, and technical expertise needed to accomplish
the required work.
3.1.2 All requirements of this specification may not apply to all
purchase orders or contracts. The extent of applicability will
be stated in the detail specifications or other procurement
document. Section 3.1 and 4 apply to all work referencing this
specification.
3.2 Propeller
3.2.1 Whenever removing a fixed-blade propeller from a tapered-end
shaft, this procedure shall be followed. When removing a
controllable-pitch propeller (CPP), follow the procedures in the
cff system manufacturer's technical manual.
3.2.2 Before removing a propeller or propeller nut, fit a shore from
the bottom of the dock to one propeller blade near the root to
take the shock of driving the propeller nut.
3.2.3 If necessary to remove the propeller and nut, heat may be applied
to the propeller hub to a maximum of 500 degrees Fahrenheit,
provided prior written approval of the COR is obtained. Before
applying heat, shield the shaft bearings from damage. When used,
heat shall be applied by two soft gas torches on opposite sides
of the hub; the flame shall be worked around the hub to heat and
expand the hub uniformly. The temperature shall be continuously
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EPA-240-1
October 2008
monitored by means of tempil sticks or contact pyrometer to
insure the hub temperature never exceeds 500 degrees Fahrenheit.
3.2.4 Follow the following procedure:
a. Remove the fairwater cap (if installed). :he 0-ring
seal (if installed) from the forward face of the propeller
hub.
b. Loosen the propeller nut a few turns but do not remove.
c. Insert drawbolts in tapped holes in the hub face if provided.
Otherwise, hook drawbolts over the blade edges or screw them
into pieces of metal laid across the forward edges of the
blade roots.
d. Place a drawbolt clamp or strongback over the end of the
shaft. Interpose a pair of steel wedges between the clamp (or
strongback) and the shaft end. Tighten down on the clamp nuts
as much as possible and drive the wedges until the propeller
starts to move. A wooden maul may be used judiciously to
release the hub.
e. Rig the propeller for handling, remove the nut, and
carefully remove the propeller from the snaft taper.
3.3 Propeller Installation
3.3.1 After verifying that the key is installed on the shaft, carefully
fit the propeller to the shaft as follows:
a. Thoroughly clean the shaft and propeller hub tapers to remove
all grit, grease, oil, dirt, rust, lint, and other foreign
particles.
b. Apply a thin even coat of prussian blue to the shaft taper
with the palm of the hand. Do not use a rag to apply the
Prussian blue because it may leave lint.
c. Carefully install the propeller onto the shaft taper. The
propeller is to be pushed firmly and snugly onto the shaft,
but is not to be driven on.
d. Remove the propeller and inspect the hub taper for the bluing
pattern transferred from the shaft taper. A pattern of 75
percent, evenly distributed around and over the entire hub,
is required. If the contact pattern is slightly heavier over
arge end of the taper, a 70-percent fit is acceptable.
In any case, the contact must be evenly distributed around
the circumference of the hub.
e. If an acceptable fit is not obtained, remove the propeller.
Grind, machine, and polish the tapered surfaces as necessary
to obtain an acceptable fit.
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EPA-240-1
October 2008
f. Repeat the above steps until an acceptable fit is obtained.
The COR shall witness the final fit to verify an acceptable
fit is obtained.
3.3.2 Clean the prussian blue from the tapers and return the propeller
onto the shaft in the same position as when the acceptable fit
was obtained. Do not apply any oil, grease, or otrier substance
to the tapers. If an O-ring and retainer were previously
installed, make sure they are inserted over the taper onto the
shaft before installing the propeller.
3.3.3 Scribe a small reference mark on the shaft to mark the
propeller's location. The reference mark must be located such
that it will be accessible while driving on the propeller.
3.3.4 Install the propeller nut and drive the propeller until it is
advanced forward on the taper a distance of 1/32-inch (0.031
inch) beyond the scribe mark. Do not apply heat to the hub while
driving on the propeller. The COR shall witness driving of the
propeller onto the shaft.
3.3.5 Lock the nut in position with locking tabs, monel lockwire, or
other method acceptable to the COR. The COR shall verify
adequacy of the locking method.
3.3.6 If applicable, install O-ring seal, seal retainer, and fairwater
cap.
3.4 Propulsion Shaft Removal and Reinstallation
3.4.1 During all handling of propulsion shafts, exercise extreme care
to prevent mechanical damage and provide adequate support to
prevent bending the shafts.
3.4.2 When rigging a shaft for removal, do not allow wire slings to
contact the shaft surfaces. Instead, slings shall be isolated
from the shaft using a material which will protect the shaft
from mechanical damage.
3.4.3 After disconnecting the shaft flanges, rotate the shaft in the
ship's bearings prior to removal and measure the shaft runout at
each end.
3.4.4 During reinstallation of the shaft, verify proper alignment at
the flange faces using "sag and gap" procedures.
3.5 In-shop Inspection of Propulsion Shaft
3
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EPA-240-1
October 2008
This procedure covers inspections required after the shaft has been
removed from the ship or boat. Unless otherwise specified elsewhere,
actual removal and reinstallation of the shaft is not required.
3.5.1 Set the shaft up in a lathe, providing supports at each bearing
surface.
3.5.2 If the shaft has removable couplings (flanged or muff), remove
the couplings.
3.5.3 Conduct the following inspections in company of the COR:
a. Complete visual inspection for mechanical defects.
b. Measure bearing liners diameters. Three measurements,
equidistant apart, shall be taken at each bearing surface
of the shaft.
c. Measure the runout of the shaft at the taper ends couplings,
and each bearing surface.
d. Measure all dimensions of the coupling to verify conformance
with the manufacturer's drawing.
e. Measure all keys and jceyways.
f. Conduct a liquid penetrant inspection of all surfaces of
shaft 1iners.
g. Conduct a magnetic particle or liquid penetrant inspection
shaft of tapers and keyways.
h. Inspect fiberglass reinforced plastic (FRP) covering (if
installed) for pinholes, porosity, and other defects by using
a high frequency spark tester. Use 250-300 volts per mil of
glass reinforcement (approximately 15,000 volts for a 4- ply
covering). Pinholes will be evidenced by bright sparks as
distinguished form the normal purplish corona.
i. Inspect the FRP covering (if installed) for proper adhesion
to Liie snaiL jjy tapping, at regular intervals of about 18
inches along the length of the covering, with a light hammer
while holding the palm of one hand against the covering on
the opposite side. Discernible vibration, movement of the
covering, or audible hollow sound is evidence of probable
loose bond.
3.5.4 Install the shaft couplings and measure the runout of the flange.
Also verify perpendicularity of the flange face with the shaft
axis .
3.6 Fiberglass Reinforced Plastic (FRP) Shaft Covering Renewal
3.6.1 Materials. When installing new FRP shaft covering, the following
materia1s shall be used:
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October 2008
a. Fiberglass cloth, conforming to MIL-Y-1140, Class C, Form 4,
fabric No. 7500. Volan A, Owens-Corning "Alraton", or Gustin-
Bacon "Methacrylic" finish, 75 filaments, are acceptable. For
shafts less than six inches in diameter, use 3-inch wide
cloth. For shafts six inches and greater in diameter, use
6-inch wide cloth.
b. Reinforcing filler for resin shall be milled glass fiber.
c. Coating resin and catalyst conforming to MIL-R- 23461, type
I.
d. Paste resin shall be automobile body filler compound or a
product equal to "Marine Tex".
e. Solvents shall be Xylol, Xylene, or Union Carbide
Cellosolve", or equal.
3.6.2 Shaft Preparation
a. Remove all existing shaft coverings and coatings in area to
receive the new FRP covering by sandblasting or machining.
Wash the shaft surface thoroughly with a solvent to remove
all oil, grease, dirt, and other foreign particles.
b. Inspect the shaft for pitting, mechanical damage, and other
conditions which may have an impact on the shafts reliability
or which will interfere with the FRP installation. Fill in
small pits with polyester or epoxy paste repair compound
which is to be mixed, applied and cured according to the
manufacturer's printed instructions.
c. Verify that the shaft liners have been machined in according
with the details on the applicable shaft drawing. If the
liners are not machined according to the drawing, contact the
COR prior to proceeding.
d. When specifically required in the detail specifications or
otner procurement document, machine the shaft 1iners ends in
accordance with attached Figure 1.
e. App±y paste to the junction of the bearing 1iner ends and the
onuj-t, fairing it in evenly. Sand the paste smooth after it
is fully cured.
3.6.3 Material Application
a. Four plies (two overlapping runs) of fiberglass cloth
covering are required. The approximate length of glass cloth
needed for each wrap, allowing some excess, can be found from
the following equation:
L= 7 DH
W
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EPA-240-1
October 2008
Where: L= length of tape required for each wrap, in feet.
D= diameter of shaft, in inches.
H= length of shaft to be covered, in
W= width of glass cloth, in inches.
The total length required for four plies is 2L.
b. Prepare a batch of resin and brush on one coat to the
prepared shaft according to the manufacturer's printed
instruction.
c. Apply the dry cloth, starting at one end of the shaft, on the
taper of the liner or as close to the flange as possible.
Wind the cloth in a spiral until the complete straight
section of shaft is covered. Overlap the cloth half the
width. Wrap tightly to prevent the formation of wrinkles.
d. Impregnate the glass cloth by brushing the entire surface
with catalyzed resin. Coat the cloth uniformly and generously
so that a thorough wetting of the glass fibers is obtained.
e. Work out all entrapped air with a roller, squeegee, or other
convenient method.
f. Apply a second wrap of cloth in a manner similar to the
first, but start at the end of the shaft where the first wrap
finished. Impregnate the second wrap with catalyzed resin and
work out all entrapped, air.
g. Using two short lengths of cloth, apply two circumferential
turns to each end of the coated section of shafting,
overlapping the bearing liner taper and impregnate each wrap
separately. Coat the entire covering with an additional coat
of resin and allow it to cure in accordance with the
manufacturer's printed instructions.
h. Prepare a batch of resin containing 10 percent (by weight) of
milled glass fibers. Coat all couplings and other
discontinuities in the shafting not covered by cloth. Permit
the coating to gel. Then apply three additional coats of this
resin mixture, allowing each coat to gel before applying the
next.
i. After the entire coating has cured, pass a high frequency
spark tester slowly over the entire covering, paying
particular attention to couplings and bearing liner junctions
with the shaft. Use 250-300 volts per mil of glass
reinforcement (approximately 15,000 volts for a 4-ply
covering). Pinholes will be evidenced by bright sparks as
distinguished form the normal purplish corona.
j . If pinholes or other defects are found, lightly sand the
surface of the coating. Prepare a small batch of resin
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EPA-240-1
October 2008
without the fibers and paint the entire coating, paying
particular attention to the the areas that showed sparking,
k. Repeat the preceding two steps until a no bright sparks are
evident during the spark test.
4. QUALITY ASSURANCE
4.1 Within 24 hours after completion of inspections and tests, prepare and
submit to the COR a condition report which contains the following:
4.1.1 A complete record of all measurements taken, compared to the
original dimension.
4.1.2 A record documenting the results of all visual and other NDT
inspections.
4.1.3 Recommendations of additional work and materials deemed to be
needed, if any, to return the shaft or propeller to good
re1iable condition.
4.2 The COR shall be advised at least 8 hours in advance of all
inspections, tests, and other work required herein to be witness by the
COR.
4.3 All NDT shall be in accordance with MIL-STD-271F, including compliance
with the requirements for qualification of NDT personnel, procedures,
and equipment. Workers performing NDT shall be certified as Level two
craftsmen by the American Society of Non-Destructive Testing in
accordance with Recommended Practice No. SNT TC-1A, 198 0 edition.
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October 2008
Shaft sleeve for sleeve thickness X, where x=3/8* or less
Gnoft Sleeve for Sleeve thickness X, Where X = 7/16' or greater
FIGURE 1
END OF SPECIFICATION
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CONTRACT NUMBER:
Item
Weight
Space
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Vertical
Centerline
Chart Table
160
Pilot House
fr 13 - 15
1 "7 '
3 ' port
Console
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S0700/SWBS997(o6/oi)
UStPA DOCKING KtPOKI
Page 1 of 2
Contract No:
Contractor:
Ship's Name:
Date:
Type of Dock:
Docking Plan No.:
Docking Position:
Docking Date:
Time:
Remarks:
Hull:
u Steel
LI Wood
Condition as Found:
PORT SIDE
STARBOARD SIDE
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= Areas of Pitting
F =
Loose Fasteners
C = Damaged Coating System
W = Deteriorated Welding
S =
Leaking Seams
Brief Description:
Recommended Repairs:
Cost Estimate:
Repairs/Alterations Made:
PORT SIDE
TAR BOARD SIDE
WL—
&
h
-I
^—WL
Brief Description:
PAINTING
Under
Recomm endation
Hand
Power
Blast
Primer
Repaint Ft2
Top
Scrape
Tool
Clean
AC
AF
REMARKS
Primer
Boot Top
Anti-corrosive
Underwater Body
LL tL
/\n ti-fou ling
Cost Estimate:
PROPOSED PAINTING
Manufacturer
Form ula
No. of Coats @ DFT
Specification
COLOR
Q_
O
Primer
I-
I-
o
Anti-corrosive
o
CD
Anti-fou ling
CL
Lll
a: *
a \a
q <
Primer
Anti-corrosive
^5
Anti-fou ling
REMARKS:
Page 26 of 27
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